AU2022314232A1

AU2022314232A1 - Aerosol generating composition

Info

Publication number: AU2022314232A1
Application number: AU2022314232A
Authority: AU
Inventors: Benjamin Jenkins; Jennifer Louise SCIROCCO
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2021-07-22
Filing date: 2022-07-22
Publication date: 2024-01-18
Also published as: EP4373307A1; WO2023002018A1; CA3223519A1; IL309494A; KR20240036572A

Abstract

The invention provides an aerosol-generating material comprising: from about 7 to about 13 wt% aerosol-generating agent, binder, from about 35 to about 50 wt% flavour, and filler. The invention also provides an aerosol-generating composition comprising the aerosol-generating material, a consumable comprising the aerosol- generating composition, a non-combustible aerosol provision system comprising the consumable, and the use of the aerosol-generating material or the aerosol- generating composition for generating an aerosol. The invention also provides a slurry that may be used to produce the aerosol-generating material, a method of making the aerosol-generating material, and aerosol-generating materials obtainable by the methods of the invention.

Description

AEROSOL GENERATING COMPOSITION

Technical Field

The present invention relates to aerosol-generating materials, aerosol- generating compositions comprising an aerosol-generating material; consumables for use within a non-combustible aerosol provision system, the consumables comprising the aerosol-generating composition; and non-combustible aerosol provision systems. The invention also relates to a slurry which may be used to produce the aerosol-generating material, methods for producing aerosol-generating materials, and aerosol-generating materials obtainable by the methods of the invention.

Background

Smoking consumables such as cigarettes, cigars and the like burn tobacco during use to create tobacco smoke. Alternatives to these types of consumables release an inhalable aerosol or vapour by releasing compounds from a substrate material by heating without burning. These may be referred to as non-combustible smoking consumables or aerosol generating assemblies. One example of such a product is a heating device which releases compounds by heating, but not burning, a solid aerosol-generating material. This solid aerosol-generating material may, in some cases, contain a botanical material. The heating volatilises at least one component of the material, typically forming an inhalable aerosol. These products may be referred to as heat-not-burn devices, tobacco heating devices or tobacco heating products. Various different arrangements for volatilising at least one component of the solid aerosol-generating material are known.

As another example, there are hybrid devices. These contain a liquid source (which may or may not contain nicotine) which is vaporised by heating to produce an inhalable vapour or aerosol. The device additionally contains a solid aerosol generating material (which may or may not contain a tobacco material) and components of this material are entrained in the inhalable vapour or aerosol to produce the inhaled medium. Summary

According to a first aspect of the present invention, there is provided an aerosol-generating material comprising: - aerosol-generating agent in an amount of from about 7 to about 13 wt% of the aerosol-generating material on a dry weight basis; binder;

- flavour in an amount of from about 35 to about 50 wt% of the aerosol generating material on a dry weight basis; and - filler.

In a second aspect, there is provided an aerosol-generating composition comprising the aerosol-generating material of the first aspect. According to a further aspect of the present invention, there is provided a consumable for use within a non-combustible aerosol provision system, the consumable comprising the aerosol-generating composition as defined herein.

According to a further aspect of the present invention, there is provided a non- combustible aerosol provision system comprising the consumable as defined herein and a non-combustible aerosol provision device, the non-combustible aerosol provision device comprising an aerosol-generation device configured to (or arranged to) generate aerosol from the consumable when the consumable is used with the non-combustible aerosol provision device.

According to a further aspect of the invention, there is provided the use of an aerosol-generating composition as defined herein in a consumable for use in a non combustible aerosol provision device, the non-combustible aerosol provision device comprising an aerosol-generation device arranged to generate aerosol from the consumable when the consumable is used with the non-combustible aerosol provision device. According to a further aspect of the invention, there is provided the use of an aerosol-generating material or an aerosol-generating composition as defined herein for generating an aerosol. According to a further aspect of the present invention, there is provided a method of making an aerosol-generating material or an aerosol-generating composition as described herein.

According to a further aspect, the invention provides an aerosol-generating material obtainable by, or obtained by, a method of the invention.

According to a further aspect of the present invention, there is provided a method of generating an aerosol using a non-combustible aerosol provision system as described herein, the method comprising heating the aerosol-generating material. In some embodiments, the method comprises heating the aerosol-generating material to a temperature of less than or equal to 350 °C. In some embodiments, the method comprises heating the aerosol-generating material to a temperature of from about 220 °C to about 280 °C. Further features and advantages of the invention will become apparent from the following description of preferred embodiments of the invention, given by way of example only, which is made with reference to the accompanying drawings.

Brief Description of the Drawings Figure 1 shows a section view of an example of an aerosol-generating article.

Figure 2 shows a perspective view of the article of Figure 1.

Figure 3 shows a sectional elevation of an example of an aerosol-generating article.

Figure 4 shows a perspective view of the article of Figure 3.

Figure 5 shows a perspective view of an example of an aerosol generating assembly. Figure 6 shows a section view of an example of an aerosol generating assembly. Figure 7 shows a perspective view of an example of an aerosol generating assembly. Figure 8 shows an exploded diagram of an example consumable.

Figure 9 shows an example of a consumable comprising a plurality of discrete portions of aerosol-generating material. Detailed Description

The aerosol-generating materials/compositions described herein are materials/compositions that are capable of generating aerosol, for example when heated, irradiated or energized in any other way. The aerosol-generating composition may, for example, be in the form of a solid, liquid or gel which may or may not contain nicotine. The aerosol-generating composition comprises an aerosol-generating material. The aerosol-generating material may be an “amorphous solid”. In some embodiments, the amorphous solid is a “monolithic solid”. The aerosol-generating material may be non-fibrous or fibrous. In some embodiments, the aerosol generating material may be a dried gel. The aerosol-generating material may be a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the aerosol-generating composition may for example comprise from about 50wt%, 60wt% or 70wt% of aerosol-generating material, to about 90wt%, 95wt% or 100wt% of aerosol-generating material. In some cases, the aerosol generating composition consists of aerosol-generating material.

As described hereinabove, the invention provides an aerosol-generating material comprising: aerosol-generating agent in an amount of from about 7 to about 13 wt% of the aerosol-generating material on a dry weight basis; - binder;

- flavour in an amount of from about 35 to about 50 wt% of the aerosol generating material on a dry weight basis; and

- filler. In some cases, the aerosol-generating material comprises: aerosol-generating agent in an amount of from about 7 to about 13 wt% of the aerosol-generating material; binder in an amount of from about 1 to about 57 wt% of the aerosol- generating material;

- flavour in an amount of from about 35 to about 50 wt% of the aerosol generating material; and

- filler in an amount of from about 1 to about 50 wt% of the aerosol generating material; wherein these amounts are calculated on a dry weight basis.

The inventors have established that flavour loss during the production of aerosol-generating materials can be reduced by controlling the amount of aerosol generating agent (such as glycerol) and flavour (such as menthol) within the claimed ranges. The aerosol-generating material disclosed herein comprises a relatively low amount of aerosol-generating agent (such as glycerol). Without wishing to be bound by theory, it is believed that flavour (such as menthol) and aerosol-generating agent (such as glycerol) may compete for emulsification sites in aerosol-generating materials, and so reducing the amount of aerosol-generating agent may result in increased retention of flavour. Reducing flavour loss during the production of aerosol generating materials reduces waste and is more cost effective.

Moreover, the amount of flavour (such as menthol) retained in the materials of the present invention may be less variable. This is advantageous for the consumer since the material constitution (and therefore the aerosol produced) may be more consistent between different batches of aerosol-generating material.

The aerosol-generating material may comprise about 7 wt%, 8wt%, 9wt%, 10wt%, or 10.3wt% to about 13wt%, 12wt%, or 11wt% of aerosol-generating agent (all calculated on a dry weight basis). In exemplary embodiments, the aerosol generating material comprises 8-13 wt%, 9-12wt%, 10-12wt%, more than 10wt% to less than 12wt%, or 10.3-11.9wt% of aerosol-generating agent (all calculated on a dry weight basis). These amounts represent the total amount of aerosol-generating agent(s) in the aerosol-generating material. In some embodiments, the aerosol-generating agent may comprise one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In some cases, the aerosol-generating agent comprises, consists essentially of or consists of glycerol. The aerosol-generating material may comprise an amount of about 1wt%,

5wt%, 10wt%, 12wt%, 15wt%, 17wt%, 19wt% or 20wt% to about 25wt%, 27 wt%, 30wt%, 40wt%, 45wt%, 50wt% or 57wt% of binder (all calculated on a dry weight basis). For example, the aerosol-generating material may comprise an amount of 1-57 wt%, 5-50 wt%, 15-35wt%, 20-30wt% or 20-25wt% of binder (dry weight basis). These amounts represent the total amount of binder(s) in the aerosol-generating material.

The binder may include a cellulosic binder and/or a non-cellulosic binder. Examples of cellulosic binders which may be used include, but are not limited to, hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose (CMC), hydroxypropyl methylcellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), and cellulose acetate propionate (CAP). Examples of non-cellulosic binders which may be used include alginates, pectins, starches (and derivatives), gums, silica or silicones compounds, clays, polyvinyl alcohol and combinations thereof.

In some embodiments, the binder is selected from the group consisting of alginates, pectins, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol.

In some embodiments, the binder comprises alginate and/or pectin.

In some embodiments, the binder comprises, consists essentially of, or consists of alginate and pectin. In some embodiments, the binder includes cellulosic binder and non- cellulosic binder. The use of cellulosic binder (e.g. CMC) in combination with non- cellulosic binder may increase the temperature at which flavour (such as menthol) is released. The lists of suitable cellulosic and non-cellulosic binders above apply equally to this embodiment. In some embodiments, the cellulosic binder comprises, or consists or, CMC and/or the non-cellulosic binder comprises, or consists or, alginate and/or guar gum. In particular embodiments, the binder comprises, consists essentially of, or consists of CMC, alginate and guar gum.

In some embodiments, the aerosol-generating material comprises a crosslinking agent. In some cases, the crosslinking agent comprises calcium ions. In some embodiments, the crosslinking agent comprises calcium lactate and/or calcium acetate. In some embodiments, the crosslinking agent comprises calcium lactate. In some cases, the aerosol-generating material may comprise a calcium-crosslinked alginate. The crosslinking agent may also be described as a setting agent.

The aerosol-generating material may comprise about 0.5wt%, 1wt%, 3wt% or 5wt% to about 10wt%, 9wt%, 8 wt% or 7wt% of crosslinking agent (all calculated on a dry weight basis). For example, the aerosol-generating material may comprise 1-10 wt%, 3-8 wt% or 5-7 wt% of crosslinking agent (dry weight basis). These amounts represent the total amount of crosslinking agent(s) in the aerosol-generating material. In some embodiments, the aerosol-generating material does not comprise a crosslinking agent.

The aerosol-generating material may be substantially free of cellulosic binder. “Substantially free” means that material comprises less than 1wt%, such as less than 0.5wt% of the relevant component (dry weight basis). In some embodiments, the aerosol-generating material does not comprise a cellulosic binder. The aerosol-generating material may be substantially free of carboxymethylcellulose (CMC). In some embodiments, the aerosol-generating material does not comprise CMC. In some embodiments, the binder comprises alginate, and the alginate is present in the aerosol-generating material in an amount of 5-50wt%, 8-40wt%, 10-30wt%, or 15-25% of the aerosol-generating material (calculated on a dry weight basis). In some embodiments, alginate is the only binder present in the aerosol generating material. In other embodiments, the binder comprises alginate and at least one further non-cellulosic binder, such as pectin.

In some embodiments, the binder comprises pectin, and the pectin is present in the aerosol-generating material in an amount of 1-10wt%, 2-8%, or 3-7% of the aerosol-generating material (calculated on a dry weight basis).

In some embodiments, the binder comprises alginate and pectin, and the alginate is present in the aerosol-generating material in an amount of 5-50wt%, 8-40wt%, 10-30wt%, or 15-25% of the aerosol-generating material, and the pectin is present in the aerosol-generating material in an amount of 1-10wt%, 2-8%, or 3-7% of the aerosol-generating material (calculated on a dry weight basis).

In some embodiments, the binder comprises alginate and pectin, and the alginate is present in the aerosol-generating material in an amount of 8-40wt% and the pectin is present in the aerosol-generating material in an amount of 1-10wt% of the aerosol-generating material (calculated on a dry weight basis).

In some embodiments, the binder comprises alginate and pectin, and the alginate is present in the aerosol-generating material in an amount of 10-30wt% and the pectin is present in the aerosol-generating material in an amount of 2-8wt% of the aerosol-generating material (calculated on a dry weight basis).

In some embodiments, the binder comprises alginate and pectin, and the alginate is present in the aerosol-generating material in an amount of 15-25wt% and the pectin is present in the aerosol-generating material in an amount of 3-7wt% of the aerosol-generating material (calculated on a dry weight basis).

The aerosol-generating material may comprise about 35wt%, 36 wt% or 37wt% to about 50wt%, 45wt% or 43wt% of flavour (all calculated on a dry weight basis). For example, the aerosol-generating material may comprise 35-45wt%, 36- 45wt%, or 37-43wt% of flavour. These amounts represent the total amount of flavour(s) in the aerosol-generating material. As used herein, the terms “flavour” and “flavourant” refer to materials which, where local regulations permit, may be used to create a desired taste, aroma, or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas. In some embodiments, the flavour comprises menthol, spearmint and/or peppermint. In some embodiments, the flavour comprises, consists essentially of or consists of menthol.

In some embodiments, the aerosol-generating material comprises from about 1wt%, 5wt%, 10wt%, 18wt% or 20wt% to about 50wt%, 45wt%, 40wt%, 35wt% or

30wt% of filler (all calculated on a dry weight basis). For example, the aerosol generating material may comprise 5-45wt%, 10-40wt%, 18-35wt% or 20-30wt% of filler (all calculated on a dry weight basis). These amounts represent the total amount of filler(s) in the aerosol-generating material.

The filler may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate, and suitable inorganic sorbents, such as molecular sieves. The filler may comprise one or more organic filler materials such as wood pulp, cellulose and cellulose derivatives. In particular cases, aerosol generating material comprises no calcium carbonate such as chalk.

In particular embodiments the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood pulp, hemp fibre, cellulose or cellulose derivatives, such as microcrystalline cellulose (MCC) and/or nanocrystalline cellulose. Without wishing to be bound by theory, it is believed that including fibrous filler in an aerosol-generating material may increase the tensile strength of the material. This may be particularly advantageous in examples wherein the aerosol generating material is provided as a sheet, such as when an aerosol-generating material sheet circumscribes a rod of aerosol-generating composition.

In some cases, the filler comprises (or is) wood pulp. In some cases, the filler comprises maltodextrin or microcrystalline cellulose (MCC). As would be well understood by the skilled person, microcrystalline cellulose may be formed by depolymerising cellulose by a chemical process (e.g. using an acid or enzyme). One example method for forming microcrystalline cellulose involves acid hydrolysis of cellulose, using an acid such as HCI. The cellulose produced after this treatment is crystalline (i.e. no amorphous regions remain). Suitable methods and conditions for forming microcrystalline cellulose are well-known in the art.

In some cases, the filler has a density of less than about 2 g/cm³, such as less than about 0.5 g/cm³ or less than about 0.3 g/cm³.

The aerosol-generating material may have any suitable water content, such as from 1wt % to 15wt%. Suitably, the water content of the aerosol-generating material may be from about 5wt%, 7wt% or 9wt% to about 15wt%, 13wt% or 11wt% (wet weight basis) (WWB). The water content of the aerosol-generating material may, for example, be determined by Karl-Fischer-titration or Gas Chromatography with Thermal Conductivity Detector (GC-TCD).

Amounts of constituents of the aerosol-generating material, such as aerosol- generating agent (e.g. glycerol) and flavourant (e,g, menthol), can be determined by gas chromatography. One example of a suitable gas chromatography protocol is set out in the Examples section below.

The aerosol-generating material may comprise a colourant. The addition of a colourant may alter the visual appearance of the aerosol-generating material. The presence of colourant in the aerosol-generating material may enhance the visual appearance of the aerosol-generating material and the aerosol-generating composition. By adding a colourant to the aerosol-generating material, the aerosol generating material may be colour-matched to other components of the aerosol- generating composition or to other components of an article comprising the aerosol generating material.

A variety of colourants may be used depending on the desired colour of the aerosol-generating material. The colour of aerosol-generating material may be, for example, white, green, red, purple, blue, brown or black. Other colours are also envisaged. Natural or synthetic colourants, such as natural or synthetic dyes, food- grade colourants and pharmaceutical-grade colourants may be used. In certain embodiments, the colourant is caramel, which may confer the aerosol-generating material with a brown appearance. In such embodiments, the colour of the aerosol generating material may be similar to the colour of other components (such as tobacco material) in an aerosol-generating composition comprising the aerosol generating material. In some embodiments, the addition of a colourant to the aerosol generating material renders it visually indistinguishable from other components in the aerosol-generating composition.

The colourant may be incorporated during the formation of the aerosol generating material (e.g. when forming a slurry comprising the materials that form the aerosol-generating material) or it may be applied to the aerosol-generating material after its formation (e.g. by spraying it onto the aerosol-generating material).

In some embodiments, the aerosol-generating composition additionally comprises an active substance. For example, in some cases, the aerosol-generating composition additionally comprises a tobacco material and/or nicotine. In some cases, the aerosol-generating composition may comprise 5-60wt% (calculated on a dry weight basis) of a tobacco material and/or nicotine. In some cases, the aerosol generating composition may comprise from about 1wt%, 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 70wt%, 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated on a dry weight basis) of an active substance. In some cases, the aerosol- generating composition may comprise from about 1wt%, 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 70wt%, 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated on a dry weight basis) of a tobacco material. For example, the aerosol generating composition may comprise 10-50wt%, 15-40wt% or 20-35wt% of a tobacco material. In some cases, the aerosol-generating composition may comprise from about 1wt%, 2wt%, 3wt% or 4wt% to about 20wt%, 18wt%, 15wt% or 12wt% (calculated on a dry weight basis) of nicotine. For example, the aerosol-generating composition may comprise 1-20wt%, 2-18wt% or3-12wt% of nicotine. In some cases, the aerosol-generating composition comprises an active substance such as tobacco extract. In some cases, the aerosol-generating composition may comprise 5-60wt% (calculated on a dry weight basis) of tobacco extract. In some cases, the aerosol-generating composition may comprise from about 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 60wt%, 50wt%, 45wt%, 40wt%,

35wt%, or 30wt% (calculated on a dry weight basis) tobacco extract. For example, the aerosol-generating composition may comprise 10-50wt%, 15-40wt% or 20- 35wt% of tobacco extract. The tobacco extract may contain nicotine at a concentration such that the aerosol-generating composition comprises 1wt% 1.5wt%, 2wt% or 2.5wt% to about 10wt%, 8wt%, 6wt%, 5wt%, 4.5wt% or 4wt% (calculated on a dry weight basis) of nicotine. In some embodiments, the aerosol-generating composition may comprise 1-10 wt%, 2.5-8 wt% or 2-6wt% nicotine. In some cases, there may be no nicotine in the aerosol-generating composition other than that which results from the tobacco extract.

In some embodiments, the aerosol-generating composition comprises no tobacco material but does comprise nicotine. In some such cases, the aerosol generating composition may comprise from about 1wt%, 2wt%, 3wt% or 4wt% to about 20wt%, 18wt%, 15wt% or 12wt% (calculated on a dry weight basis) of nicotine. For example, the aerosol-generating composition may comprise 1-20wt%, 2-18wt% or 3-12wt% of nicotine.

The aerosol-generating composition may comprise an acid. The acid may be an organic acid. In some of these embodiments, the acid may be at least one of a monoprotic acid, a diprotic acid and a triprotic acid. In some such embodiments, the acid may contain at least one carboxyl functional group. In some such embodiments, the acid may be at least one of an alpha-hydroxy acid, carboxylic acid, dicarboxylic acid, tricarboxylic acid and keto acid. In some such embodiments, the acid may be an alpha-keto acid.

In some such embodiments, the acid may be at least one of succinic acid, lactic acid, benzoic acid, citric acid, tartaric acid, fumaric acid, levulinic acid, acetic acid, malic acid, formic acid, sorbic acid, benzoic acid, propanoic and pyruvic acid. Suitably the acid is lactic acid. In other embodiments, the acid is benzoic acid. In other embodiments the acid may be an inorganic acid. In some of these embodiments the acid may be a mineral acid. In some such embodiments, the acid may be at least one of sulphuric acid, hydrochloric acid, boric acid and phosphoric acid. In some embodiments, the acid is levulinic acid.

Inclusion of an acid is particularly preferred in embodiments in which the aerosol-generating composition comprises nicotine. The presence of the acid may reduce or substantially prevent evaporation of nicotine during drying of the slurry, thereby reducing loss of nicotine during manufacturing. The presence of the acid may also improve the flavour of the aerosol when nicotine is present. For example, the perceived harshness of the nicotine may be reduced by the presence of the acid.

In some embodiments, the aerosol-generating material is substantially free from tobacco. By “substantially free from” it is meant that the material comprises less than 1wt%, such as less than 0.5wt% tobacco (dry weight basis). In some embodiments, the aerosol-generating material is free from tobacco. In some embodiments, the aerosol-generating material does not comprise tobacco fibres. In particular embodiments, the aerosol-generating material does not comprise fibrous material.

In some embodiments, the aerosol-generating composition does not comprise tobacco fibres. In particular embodiments, the aerosol-generating composition does not comprise fibrous material.

In some embodiments, the aerosol-generating article does not comprise tobacco fibres. In particular embodiments, the aerosol-generating article does not comprise fibrous material. The aerosolisable or aerosol-generating material may be present on or in a support to form a substrate. The support functions as a support on which the aerosol generating material layer forms, easing manufacture. The support may provide rigidity to the aerosol-generating material layer, easing handling. The support may be any suitable material which can be used to support an aerosol-generating material. In some cases, the support may be formed from materials selected from metal foil, paper, carbon paper, greaseproof paper, ceramic, carbon allotropes such as graphite and graphene, plastic, cardboard, wood or combinations thereof. In some cases, the support may comprise or consist of a tobacco material, such as a sheet of reconstituted tobacco. In some cases, the support may be formed from materials selected from metal foil, paper, cardboard, wood or combinations thereof. In some cases, the support comprises paper. In some cases, the support itself may be a laminate structure comprising layers of materials selected from the preceding lists. In some cases, the support may also function as a flavour support. For example, the support may be impregnated with a flavourant or with tobacco extract.

Suitably, the thickness of the support layer may be in the range of about 10pm, 15pm, 17pm, 20pm, 23pm, 25pm, 50pm, 75pm or 0.1mm to about 2.5mm,

2.0mm, 1.5mm, 1.0mm or 0.5mm. The support may comprise more than one layer, and the thickness described herein refers to the aggregate thickness of those layers.

In some cases, the support may be magnetic. This functionality may be used to fasten the support to the assembly in use, or may be used to generate particular aerosol-generating material shapes. In some cases, the aerosol-generating substrate may comprise one or more magnets which can be used to fasten the substrate to an induction heater in use. In some cases, the support may be substantially or wholly impermeable to gas and/or aerosol. This prevents aerosol or gas passage through the support layer, thereby controlling the flow and ensuring it is delivered to the user. This can also be used to prevent condensation or other deposition of the gas/aerosol in use on, for example, the surface of a heater provided in an aerosol generating assembly. Thus, consumption efficiency and hygiene can be improved in some cases.

In some cases, the surface of the support that abuts the aerosol-generating material may be porous. For example, in one case, the support comprises paper. A porous support such as paper is particularly suitable for the present invention; the porous (e.g. paper) layer abuts the aerosol-generating layer and forms a strong bond. The aerosol-generating material is formed by drying a gel and, without being limited by theory, it is thought that the slurry from which the gel is formed partially impregnates the porous support (e.g. paper) so that when the gel sets and forms cross-links, the support is partially bound into the gel. This provides a strong binding between the gel and the support (and between the dried gel and the support).

Additionally, surface roughness may contribute to the strength of bond between the aerosol-generating material and the support. The paper roughness (for the surface abutting the support) may suitably be in the range of 50-1000 Bekk seconds, suitably 50-150 Bekk seconds, suitably 100 Bekk seconds (measured over an air pressure interval of 50.66-48.00 kPa). (A Bekk smoothness tester is an instrument used to determine the smoothness of a paper surface, in which air at a specified pressure is leaked between a smooth glass surface and a paper sample, and the time (in seconds) for a fixed volume of air to seep between these surfaces is the "Bekk smoothness”.)

Conversely, the surface of the support facing away from the aerosol generating material may be arranged in contact with the heater, and a smoother surface may provide more efficient heat transfer. Thus, in some cases, the support is disposed so as to have a rougher side abutting the aerosol-generating material and a smoother side facing away from the aerosol-generating material.

In one particular case, the support may be a paper-backed foil; the paper layer abuts the aerosol-generating material layer and the properties discussed in the previous paragraphs are afforded by this abutment. The foil backing is substantially impermeable, providing control of the aerosol flow path. A metal foil backing may also serve to conduct heat to the aerosol-generating material. In another case, the foil layer of the paper-backed foil abuts the aerosol generating material. The foil is substantially impermeable, thereby preventing water provided in the aerosol-generating material to be absorbed into the paper which could weaken its structural integrity. In some cases, the support is formed from or comprises metal foil, such as aluminium foil. A metallic support may allow for better conduction of thermal energy to the aerosol-generating material. Additionally, or alternatively, a metal foil may function as a susceptor in an induction heating system. In particular embodiments, the support comprises a metal foil layer and a support layer, such as cardboard. In these embodiments, the metal foil layer may have a thickness of less than 20pm, such as from about 1pm to about 10pm, suitably about 5pm.

In some cases, the support may have a thickness of between about 0.017mm and about 2.0mm, suitably from about 0.02mm, 0.05mm or 0.1mm to about 1.5mm, 1.0mm, or 0.5mm.

The aerosol-generating material may be made from a gel, and this gel may additionally comprise a solvent, included at 0.1-50wt%. However, the inclusion of a solvent in which the flavour is soluble may reduce the gel stability and the flavour may crystallise out of the gel. As such, in some cases, the gel does not include a solvent in which the flavour is soluble.

An aspect of the present invention relates to an article (also referred to herein as a consumable). A consumable is an article, part or all of which is intended to be consumed during use by a user. A consumable may comprise or consist of aerosol generating composition. A consumable may comprise one or more other elements, such as a filter or an aerosol modifying substance. A consumable may comprise a heating element that emits heat to cause the aerosol-generating composition to generate aerosol in use. The heating element may, for example, comprise combustible material, or may comprise a susceptor that is heatable by penetration with a varying magnetic field.

Articles of the present invention may be provided in any suitable shape. In some examples, the article is provided as a rod (e.g. substantially cylindrical). An article provided as a rod may include the aerosol-generating composition as a shredded sheet, optionally blended with cut tobacco. Alternatively, or additionally, the article provided as a rod may include the aerosol-generating composition as a sheet, such as a sheet circumscribing a rod of aerosol-generating material (e.g. tobacco, or a combination of tobacco and an aerosol-generating material such as that described herein). In some embodiments, the article comprises a layer portion of aerosol generating composition disposed on a carrier. In examples, the article may have at least one substantially planar (flat) surface.

The aerosol-generating material may comprise or be in the form of an aerosol-generating film. The aerosol-generating film may be substantially free from botanical material. In particular, in some embodiments, the aerosol-generating film is substantially tobacco free.

The aerosol-generating film may have a thickness of about 0.015 mm to about 1 mm. For example, the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm. The aerosol-generating film may be continuous. For example, the film may comprise or be a continuous sheet of material. The sheet may be in the form of a wrapper, it may be gathered to form a gathered sheet or it may be shredded to form a shredded sheet. The shredded sheet may comprise one or more strands or strips of aerosol-generating material.

In one case, the aerosol-generating film is shredded and blended with another shredded aerosol-generating film.

In one case, there is provided a consumable for use in a non-combustible aerosol-provision system comprising a planar support with complete coverage of the aerosol-generating material (e.g. a continuous aerosol-generating film). Figure 8 provides a schematic illustration of such a consumable, which includes a support layer 4 and an aerosol-generating material layer 2. The aerosol-generating film may be discontinuous. For example, the aerosol-generating film may comprise one or more discrete portions or regions of aerosol-generating material, such as dots, stripes or lines, which may be supported on a support. In such embodiments, the support may be planar or non-planar. In some cases, the discrete portions of aerosol-generating material are substantially round, cylindrical or hemispherical. In some cases, there is a grid shaped distribution of the substantially round, cylindrical or hemispherical aerosol generating material.

In some cases, there is provided a consumable for use in a non-combustible aerosol-provision system comprising a planar support with a discontinuous aerosol generating film (which comprises a plurality of discrete portions of aerosol generating material) deposited on it.

Figure 9 provides an example of a consumable (401) wherein a discontinuous aerosol-generating film (which comprises a discrete portion of aerosol-generating material (403)) are provided on the consumable. A susceptor is material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The heating material may be an electrically-conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the heating material. The heating material may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the heating material. The heating material may be both electrically-conductive and magnetic, so that the heating material is heatable by both heating mechanisms.

Induction heating is a process in which an electrically-conductive object is heated by penetrating the object with a varying magnetic field. The process is described by Faraday's law of induction and Ohm's law. An induction heater may comprise an electromagnet and a device for passing a varying electrical current, such as an alternating current, through the electromagnet. When the electromagnet and the object to be heated are suitably relatively positioned so that the resultant varying magnetic field produced by the electromagnet penetrates the object, one or more eddy currents are generated inside the object. The object has a resistance to the flow of electrical currents. Therefore, when such eddy currents are generated in the object, their flow against the electrical resistance of the object causes the object to be heated. This process is called Joule, ohmic, or resistive heating. In some embodiments, the susceptor is in the form of a closed circuit. It has been found that, when the susceptor is in the form of a closed circuit, magnetic coupling between the susceptor and the electromagnet in use is enhanced, which results in greater or improved Joule heating.

Magnetic hysteresis heating is a process in which an object made of a magnetic material is heated by penetrating the object with a varying magnetic field. A magnetic material can be considered to comprise many atomic-scale magnets, or magnetic dipoles. When a magnetic field penetrates such material, the magnetic dipoles align with the magnetic field. Therefore, when a varying magnetic field, such as an alternating magnetic field, for example as produced by an electromagnet, penetrates the magnetic material, the orientation of the magnetic dipoles changes with the varying applied magnetic field. Such magnetic dipole reorientation causes heat to be generated in the magnetic material.

When an object is both electrically-conductive and magnetic, penetrating the object with a varying magnetic field can cause both Joule heating and magnetic hysteresis heating in the object. Moreover, the use of magnetic material can strengthen the magnetic field, which can intensify the Joule heating.

In each of the above processes, as heat is generated inside the object itself, rather than by an external heat source by heat conduction, a rapid temperature rise in the object and more uniform heat distribution can be achieved, particularly through selection of suitable object material and geometry, and suitable varying magnetic field magnitude and orientation relative to the object. Moreover, as induction heating and magnetic hysteresis heating do not require a physical connection to be provided between the source of the varying magnetic field and the object, design freedom and control over the heating profile may be greater, and cost may be lower.

The thickness values stipulated herein are mean values for the thickness in question. In some cases, the thickness may vary by no more than 25%, 20%, 15%, 10%, 5% or 1%. The “thickness” of the aerosol-generating material describes the shortest distance between a first surface and a second surface. In embodiments where the aerosol-generating material is in the form of a sheet, the thickness of the aerosol generating material is the shortest distance between a first planar surface of the sheet and a second planar surface of the sheet which opposes the first planar surface of the sheet. In some cases, the aerosol-generating composition may have a thickness of about 0.015mm to about 1.0mm. Suitably, the thickness may be in the range of about0.05mm, 0.1mm or0.15mm to about0.5mm or0.3mm. The aerosol-generating material may comprise more than one layer, and the thickness described herein refers to the aggregate thickness of those layers.

In some cases, the aerosol-generating material may have a thickness of about 0.015mm to about 1.0mm. Suitably, the thickness may be in the range of about 0.05mm, 0.1mm or 0.15mm to about 0.5mm or 0.3mm. The aerosol-generating material may comprise more than one layer, and the thickness described herein refers to the aggregate thickness of those layers.

The aerosol-generating composition comprising the aerosol-generating material may have any suitable area density, such as from 30 g/m² to 120 g/m². In some embodiments, aerosol-generating composition may have an area density of from about 30 to 70 g/m², or about 40 to 60 g/m². In some embodiments, the aerosol generating composition may have an area density of from about 80 to 120 g/m², or from about 70 to 110 g/m², or particularly from about 90 to 110 g/m². Such area densities may be particularly suitable where the aerosol-generating composition is included in an aerosol-generating article/assembly in sheet form, or as a shredded sheet (described further hereinbelow).

An aspect of the invention provides non-combustible aerosol provision system comprising an article according as described herein and non-combustible aerosol provision device comprising a heater which is configured to heat not burn the aerosol-generating article. A non-combustible aerosol provision system may also be referred to as an aerosol generating assembly. A non-combustible aerosol provision device may be referred to as an aerosol generating apparatus. In some cases, in use, the heater may heat, without burning, the aerosol generating material to a temperature equal to or less than 350 °C, such as between 120°C and 350 °C. In some cases, the heater may heat, without burning, the aerosol generating composition to between 140 °C and 250 °C in use, or between 220 °C and 280 °C. In some cases in use, substantially all of the aerosol-generating material is less than about 4mm, 3mm, 2mm or 1mm from the heater. In some cases, the material is disposed between about 0.010mm and 2.0mm from the heater, suitably between about 0.02mm and 1.0mm, suitably 0.1mm to 0.5mm. These minimum distances may, in some cases, reflect the thickness of a support that supports the aerosol-generating material. In some cases, a surface of the aerosol-generating material may directly abut the heater.

The heater is configured to heat not burn the aerosol-generating article, and thus the aerosol-generating composition. The heater may be, in some cases, a thin film, electrically resistive heater. In other cases, the heater may comprise an induction heater or the like. The heater may be a combustible heat source or a chemical heat source which undergoes an exothermic reaction to product heat in use. The aerosol generating assembly may comprise a plurality of heaters. The heater(s) may be powered by a battery.

The aerosol-generating article may additionally comprise a cooling element and/or a filter. The cooling element, if present, may act or function to cool gaseous or aerosol components. In some cases, it may act to cool gaseous components such that they condense to form an aerosol. It may also act to space the very hot parts of the non-combustible aerosol provision device from the user. The filter, if present, may comprise any suitable filter known in the art such as a cellulose acetate plug.

In some cases, the aerosol generating assembly may be a heat-not-burn device. That is, it may contain a solid aerosol-generating material (and no liquid aerosol-generating material). In some cases, the aerosol-generating material may comprise the tobacco material. A heat-not-burn device is disclosed in WO 2015/062983 A2, which is incorporated by reference in its entirety. In some cases, the aerosol generating assembly may be an electronic tobacco hybrid device. That is, it may contain a solid aerosol-generating composition and a liquid aerosol-generating material. In some cases, the aerosol-generating material may comprise nicotine. In some cases, the aerosol-generating material may comprise a tobacco material. In some cases, the aerosol-generating material may comprise a tobacco material and a separate nicotine source. The separate aerosol generating compositions may be heated by separate heaters, the same heater or, in one case, a downstream aerosol-generating material may be heated by a hot aerosol which is generated from the upstream aerosol-generating composition. An electronic tobacco hybrid device is disclosed in WO 2016/135331 A1, which is incorporated by reference in its entirety.

The aerosol-generating article (which may be referred to herein as an article, a cartridge or a consumable) may be adapted for use in a THP, an electronic tobacco hybrid device or another aerosol generating device. In some cases, the article may additionally comprise a filter and/or cooling element (which have been described above). In some cases, the aerosol-generating article may be circumscribed by a wrapping material such as paper. The aerosol-generating article may additionally comprise ventilation apertures. These may be provided in the sidewall of the article. In some cases, the ventilation apertures may be provided in the filter and/or cooling element. These apertures may allow cool air to be drawn into the article during use, which can mix with the heated volatilised components thereby cooling the aerosol.

The ventilation enhances the generation of visible heated volatilised components from the article when it is heated in use. The heated volatilised components are made visible by the process of cooling the heated volatilised components such that supersaturation of the heated volatilised components occurs. The heated volatilised components then undergo droplet formation, otherwise known as nucleation, and eventually the size of the aerosol particles of the heated volatilised components increases by further condensation of the heated volatilised components and by coagulation of newly formed droplets from the heated volatilised components. In some cases, the ratio of the cool air to the sum of the heated volatilised components and the cool air, known as the ventilation ratio, is at least 15%. A ventilation ratio of 15% enables the heated volatilised components to be made visible by the method described above. The visibility of the heated volatilised components enables the user to identify that the volatilised components have been generated and adds to the sensory experience of the smoking experience.

In another example, the ventilation ratio is between 50% and 85% to provide additional cooling to the heated volatilised components. In some cases, the ventilation ratio may be at least 60% or 65%.

In some cases, the aerosol-generating composition may be included in the article/assembly in sheet form. In some cases, the aerosol-generating composition may be included as a planar sheet. In some cases, the aerosol-generating composition may be included as a planar sheet, as a bunched or gathered sheet, as a crimped sheet, or as a rolled sheet (i.e. in the form of a tube). In some such cases, the aerosol-generating material of these embodiments may be included in an aerosol generating article/assembly as a sheet, such as a sheet circumscribing a rod of aerosol-generating material (e.g. tobacco). In some other cases, the aerosol- generating composition may be formed as a sheet and then shredded and incorporated into the article. In some cases, the shredded sheet may be mixed with cut rag tobacco and incorporated into the article.

In some examples, the aerosol-generating material in sheet form may have a tensile strength of from around 200 N/m to around 900 N/m. In some examples, the aerosol-generating material may have a tensile strength of from 200 N/m to 400 N/m, or 200 N/m to 300 N/m, or about 250 N/m. Such tensile strengths may be particularly suitable for embodiments wherein the aerosol-generating composition is formed as a sheet and then shredded and incorporated into an aerosol-generating article. In some examples the aerosol-generating material may have a tensile strength of from 600 N/m to 900 N/m, or from 700 N/m to 900 N/m, or around 800 N/m. Such tensile strengths may be particularly suitable for embodiments wherein the aerosol generating composition is included in an aerosol-generating article/assembly as a rolled sheet, suitably in the form of a tube. In some embodiments, the aerosol-generating material is formed as a film on a support. The aerosol-generating film may be a continuous film or a discontinuous film, such as an arrangement of discrete portions of film on a support.

Referring to Figures 1 and 2, there are shown a partially cut-away section view and a perspective view of an example of an aerosol-generating article 101. The article 101 is adapted for use with a device having a power source and a heater. The article 101 of this embodiment is particularly suitable for use with the device 1 shown in Figures 5 to 7, described below. In use, the article 101 may be removably inserted into the device shown in Figure 5 at an insertion point 20 of the device 1.

The article 101 of one example is in the form of a substantially cylindrical rod that includes a body of aerosol-generating composition 103 and a filter assembly 105 in the form of a rod. The aerosol-generating composition comprises the aerosol generating material described herein. In some embodiments, it may be included in sheet form. In some embodiments it may be included in the form of a shredded sheet. In some embodiments, the aerosol-generating composition described herein may be incorporated in sheet form and in shredded form.

The filter assembly 105 includes three segments, a cooling segment 107, a filter segment 109 and a mouth end segment 111. The article 101 has a first end 113, also known as a mouth end or a proximal end and a second end 115, also known as a distal end. The body of aerosol-generating composition 103 is located towards the distal end 115 of the article 101. In one example, the cooling segment 107 is located adjacent the body of aerosol-generating composition 103 between the body of aerosol-generating composition 103 and the filter segment 109, such that the cooling segment 107 is in an abutting relationship with the aerosol-generating composition 103 and the filter segment 103. In other examples, there may be a separation between the body of aerosol-generating composition 103 and the cooling segment 107 and between the body of aerosol-generating composition 103 and the filter segment 109. The filter segment 109 is located in between the cooling segment 107 and the mouth end segment 111. The mouth end segment 111 is located towards the proximal end 113 of the article 101, adjacent the filter segment 109. In one example, the filter segment 109 is in an abutting relationship with the mouth end segment 111. In one embodiment, the total length of the filter assembly 105 is between 37mm and 45mm, more preferably, the total length of the filter assembly 105 is 41mm.

In one example, the rod of aerosol-generating composition 103 is between 34mm and 50mm in length, suitably between 38mm and 46mm in length, suitably 42mm in length. In one example, the total length of the article 101 is between 71mm and

95mm, suitably between 79mm and 87mm, suitably 83mm.

An axial end of the body of aerosol-generating composition 103 is visible at the distal end 115 of the article 101. However, in other embodiments, the distal end 115 of the article 101 may comprise an end member (not shown) covering the axial end of the body of aerosol-generating composition 103.

The body of aerosol-generating composition 103 is joined to the filter assembly 105 by annular tipping paper (not shown), which is located substantially around the circumference of the filter assembly 105 to surround the filter assembly 105 and extends partially along the length of the body of aerosol-generating composition 103. In one example, the tipping paper is made of 58GSM standard tipping base paper. In one example the tipping paper has a length of between 42mm and 50mm, suitably of 46mm.

In one example, the cooling segment 107 is an annular tube and is located around and defines an air gap within the cooling segment. The air gap provides a chamber for heated volatilised components generated from the body of aerosol generating composition 103 to flow. The cooling segment 107 is hollow to provide a chamber for aerosol accumulation yet rigid enough to withstand axial compressive forces and bending moments that might arise during manufacture and whilst the article 101 is in use during insertion into the device 1. In one example, the thickness of the wall of the cooling segment 107 is approximately 0.29mm. The cooling segment 107 provides a physical displacement between the aerosol-generating composition 103 and the filter segment 109. The physical displacement provided by the cooling segment 107 will provide a thermal gradient across the length of the cooling segment 107. In one example the cooling segment 107 is configured to provide a temperature differential of at least 40 degrees Celsius between a heated volatilised component entering a first end of the cooling segment 107 and a heated volatilised component exiting a second end of the cooling segment 107. In one example the cooling segment 107 is configured to provide a temperature differential of at least 60 degrees Celsius between a heated volatilised component entering a first end of the cooling segment 107 and a heated volatilised component exiting a second end of the cooling segment 107. This temperature differential across the length of the cooling element 107 protects the temperature sensitive filter segment 109 from the high temperatures of the aerosol-generating composition 103 when it is heated by the device 1. If the physical displacement was not provided between the filter segment 109 and the body of aerosol-generating composition 103 and the heating elements of the device 1, then the temperature sensitive filter segment may 109 become damaged in use, so it would not perform its required functions as effectively. In one example the length of the cooling segment 107 is at least 15mm. In one example, the length of the cooling segment 107 is between 20mm and 30mm, more particularly 23mm to 27mm, more particularly 25mm to 27mm, suitably 25mm.

The cooling segment 107 is made of paper, which means that it is comprised of a material that does not generate compounds of concern, for example, toxic compounds when in use adjacent to the heater of the device 1. In one example, the cooling segment 107 is manufactured from a spirally wound paper tube which provides a hollow internal chamber yet maintains mechanical rigidity. Spirally wound paper tubes are able to meet the tight dimensional accuracy requirements of high- speed manufacturing processes with respect to tube length, outer diameter, roundness and straightness.

In another example, the cooling segment 107 is a recess created from stiff plug wrap or tipping paper. The stiff plug wrap or tipping paper is manufactured to have a rigidity that is sufficient to withstand the axial compressive forces and bending moments that might arise during manufacture and whilst the article 101 is in use during insertion into the device 1. The filter segment 109 may be formed of any filter material sufficient to remove one or more volatilised compounds from heated volatilised components from the aerosol-generating material. In one example the filter segment 109 is made of a mono-acetate material, such as cellulose acetate. The filter segment 109 provides cooling and irritation-reduction from the heated volatilised components without depleting the quantity of the heated volatilised components to an unsatisfactory level for a user.

In some embodiments, a capsule (not illustrated) may be provided in filter segment 109. It may be disposed substantially centrally in the filter segment 109, both across the filter segment 109 diameter and along the filter segment 109 length. In other cases, it may be offset in one or more dimension. The capsule may in some cases, where present, contain a volatile component such as a flavourant or aerosol generating agent. The density of the cellulose acetate tow material of the filter segment 109 controls the pressure drop across the filter segment 109, which in turn controls the draw resistance of the article 101. Therefore the selection of the material of the filter segment 109 is important in controlling the resistance to draw of the article 101. In addition, the filter segment performs a filtration function in the article 101.

In one example, the filter segment 109 is made of a 8Y15 grade of filter tow material, which provides a filtration effect on the heated volatilised material, whilst also reducing the size of condensed aerosol droplets which result from the heated volatilised material.

The presence of the filter segment 109 provides an insulating effect by providing further cooling to the heated volatilised components that exit the cooling segment 107. This further cooling effect reduces the contact temperature of the user’s lips on the surface of the filter segment 109. In one example, the filter segment 109 is between 6mm to 10mm in length, suitably 8mm. The mouth end segment 111 is an annular tube and is located around and defines an air gap within the mouth end segment 111. The air gap provides a chamber for heated volatilised components that flow from the filter segment 109. The mouth end segment 111 is hollow to provide a chamber for aerosol accumulation yet rigid enough to withstand axial compressive forces and bending moments that might arise during manufacture and whilst the article is in use during insertion into the device 1. In one example, the thickness of the wall of the mouth end segment 111 is approximately 0.29mm. In one example, the length of the mouth end segment 111 is between 6mm to 10mm, suitably 8mm. The mouth end segment 111 may be manufactured from a spirally wound paper tube which provides a hollow internal chamber yet maintains critical mechanical rigidity. Spirally wound paper tubes are able to meet the tight dimensional accuracy requirements of high-speed manufacturing processes with respect to tube length, outer diameter, roundness and straightness.

The mouth end segment 111 provides the function of preventing any liquid condensate that accumulates at the exit of the filter segment 109 from coming into direct contact with a user. It should be appreciated that, in one example, the mouth end segment 111 and the cooling segment 107 may be formed of a single tube and the filter segment 109 is located within that tube separating the mouth end segment 111 and the cooling segment 107. Referring to Figures 3 and 4, there are shown a partially cut-away section and perspective views of an example of an article 301. The reference signs shown in Figures 3 and 4 are equivalent to the reference signs shown in Figures 1 and 2, but with an increment of 200. In the example of the article 301 shown in Figures 3 and 4, a ventilation region 317 is provided in the article 301 to enable air to flow into the interior of the article 301 from the exterior of the article 301. In one example the ventilation region 317 takes the form of one or more ventilation holes 317 formed through the outer layer of the article 301. The ventilation holes may be located in the cooling segment 307 to aid with the cooling of the article 301. In one example, the ventilation region 317 comprises one or more rows of holes, and preferably, each row of holes is arranged circumferentially around the article 301 in a cross-section that is substantially perpendicular to a longitudinal axis of the article 301.

In one example, there are between one to four rows of ventilation holes to provide ventilation for the article 301. Each row of ventilation holes may have between 12 to 36 ventilation holes 317. The ventilation holes 317 may, for example, be between 100 to 500pm in diameter. In one example, an axial separation between rows of ventilation holes 317 is between 0.25mm and 0.75mm, suitably 0.5mm.

In one example, the ventilation holes 317 are of uniform size. In another example, the ventilation holes 317 vary in size. The ventilation holes can be made using any suitable technique, for example, one or more of the following techniques: laser technology, mechanical perforation of the cooling segment 307 or pre perforation of the cooling segment 307 before it is formed into the article 301. The ventilation holes 317 are positioned so as to provide effective cooling to the article 301. In one example, the rows of ventilation holes 317 are located at least 11mm from the proximal end 313 of the article, suitably between 17mm and 20mm from the proximal end 313 of the article 301. The location of the ventilation holes 317 is positioned such that user does not block the ventilation holes 317 when the article 301 is in use.

Providing the rows of ventilation holes between 17mm and 20mm from the proximal end 313 of the article 301 enables the ventilation holes 317 to be located outside of the device 1, when the article 301 is fully inserted in the device 1, as can be seen in Figures 6 and 7. By locating the ventilation holes outside of the device, non-heated air is able to enter the article 301 through the ventilation holes from outside the device 1 to aid with the cooling of the article 301.

The length of the cooling segment 307 is such that the cooling segment 307 will be partially inserted into the device 1, when the article 301 is fully inserted into the device 1. The length of the cooling segment 307 provides a first function of providing a physical gap between the heater arrangement of the device 1 and the heat sensitive filter arrangement 309, and a second function of enabling the ventilation holes 317 to be located in the cooling segment, whilst also being located outside of the device 1 , when the article 301 is fully inserted into the device 1. As can be seen from Figures 6 and 7, the majority of the cooling element 307 is located within the device 1. However, there is a portion of the cooling element 307 that extends out of the device 1. It is in this portion of the cooling element 307 that extends out of the device 1 in which the ventilation holes 317 are located.

Referring now to Figures 5 to 7 in more detail, there is shown an example of a device 1 arranged to heat aerosol-generating composition to volatilise at least one component of said aerosol-generating composition, typically to form an aerosol which can be inhaled. The device 1 is a heating device which releases compounds by heating, but not burning, the aerosol-generating composition.

A first end 3 is sometimes referred to herein as the mouth or proximal end 3 of the device 1 and a second end 5 is sometimes referred to herein as the distal end 5 of the device 1. The device 1 has an on/off button 7 to allow the device 1 as a whole to be switched on and off as desired by a user.

The device 1 comprises a housing 9 for locating and protecting various internal components of the device 1. In the example shown, the housing 9 comprises a uni-body sleeve 11 that encompasses the perimeter of the device 1, capped with a top panel 17 which defines generally the ‘top’ of the device 1 and a bottom panel 19 which defines generally the ‘bottom’ of the device 1. In another example the housing comprises a front panel, a rear panel and a pair of opposite side panels in addition to the top panel 17 and the bottom panel 19. The top panel 17 and/or the bottom panel 19 may be removably fixed to the uni-body sleeve 11, to permit easy access to the interior of the device 1, or may be “permanently” fixed to the uni-body sleeve 11, for example to deter a user from accessing the interior of the device 1. In an example, the panels 17 and 19 are made of a plastics material, including for example glass-filled nylon formed by injection moulding, and the uni-body sleeve 11 is made of aluminium, though other materials and other manufacturing processes may be used.

The top panel 17 of the device 1 has an opening 20 at the mouth end 3 of the device 1 through which, in use, the article 101, 301 including the aerosol-generating composition may be inserted into the device 1 and removed from the device 1 by a user.

The housing 9 has located or fixed therein a heater arrangement 23, control circuitry 25 and a power source 27. In this example, the heater arrangement 23, the control circuitry 25 and the power source 27 are laterally adjacent (that is, adjacent when viewed from an end), with the control circuitry 25 being located generally between the heater arrangement 23 and the power source 27, though other locations are possible.

The control circuitry 25 may include a controller, such as a microprocessor arrangement, configured and arranged to control the heating of the aerosol generating composition in the article 101, 301 as discussed further below. The power source 27 may be for example a battery, which may be a rechargeable battery or a non-rechargeable battery. Examples of suitable batteries include for example a lithium-ion battery, a nickel battery (such as a nickel-cadmium battery), an alkaline battery and/ or the like. The battery 27 is electrically coupled to the heater arrangement 23 to supply electrical power when required and under control of the control circuitry 25 to heat the aerosol-generating composition in the article (as discussed, to volatilise the aerosol-generating material without causing the aerosol-generating composition to burn). An advantage of locating the power source 27 laterally adjacent to the heater arrangement 23 is that a physically large power source 25 may be used without causing the device 1 as a whole to be unduly lengthy. As will be understood, in general a physically large power source 25 has a higher capacity (that is, the total electrical energy that can be supplied, often measured in Amp-hours or the like) and thus the battery life for the device 1 can be longer.

In one example, the heater arrangement 23 is generally in the form of a hollow cylindrical tube, having a hollow interior heating chamber 29 into which the article 101, 301 comprising the aerosol-generating material is inserted for heating in use.

Different arrangements for the heater arrangement 23 are possible. For example, the heater arrangement 23 may comprise a single heating element or may be formed of plural heating elements aligned along the longitudinal axis of the heater arrangement 23. The or each heating element may be annular or tubular, or at least part-annular or part-tubular around its circumference. In an example, the or each heating element may be a thin film heater. In another example, the or each heating element may be made of a ceramics material. Examples of suitable ceramics materials include alumina and aluminium nitride and silicon nitride ceramics, which may be laminated and sintered. Other heating arrangements are possible, including for example inductive heating, infrared heater elements, which heat by emitting infrared radiation, or resistive heating elements formed by for example a resistive electrical winding.

In one particular example, the heater arrangement 23 is supported by a stainless steel support tube and comprises a polyimide heating element. The heater arrangement 23 is dimensioned so that substantially the whole of the body of aerosol generating composition 103, 303 of the article 101, 301 is inserted into the heater arrangement 23 when the article 101, 301 is inserted into the device 1.

The or each heating element may be arranged so that selected zones of the aerosol-generating material can be independently heated, for example in turn (over time, as discussed above) or together (simultaneously) as desired.

The heater arrangement 23 in this example is surrounded along at least part of its length by a thermal insulator 31. The insulator 31 helps to reduce heat passing from the heater arrangement 23 to the exterior of the device 1. This helps to keep down the power requirements for the heater arrangement 23 as it reduces heat losses generally. The insulator 31 also helps to keep the exterior of the device 1 cool during operation of the heater arrangement 23. In one example, the insulator 31 may be a double-walled sleeve which provides a low pressure region between the two walls of the sleeve. That is, the insulator 31 may be for example a “vacuum” tube, i.e. a tube that has been at least partially evacuated so as to minimise heat transfer by conduction and/or convection. Other arrangements for the insulator 31 are possible, including using heat insulating materials, including for example a suitable foam-type material, in addition to or instead of a double-walled sleeve.

The housing 9 may further comprises various internal support structures 37 for supporting all internal components, as well as the heating arrangement 23. The device 1 further comprises a collar 33 which extends around and projects from the opening 20 into the interior of the housing 9 and a generally tubular chamber 35 which is located between the collar 33 and one end of the vacuum sleeve 31. The chamber 35 further comprises a cooling structure 35f, which in this example, comprises a plurality of cooling fins 35f spaced apart along the outer surface of the chamber 35, and each arranged circumferentially around outer surface of the chamber 35. There is an air gap 36 between the hollow chamber 35 and the article 101, 301 when it is inserted in the device 1 over at least part of the length of the hollow chamber 35. The air gap 36 is around all of the circumference of the article 101, 301 over at least part of the cooling segment 307.

The collar 33 comprises a plurality of ridges 60 arranged circumferentially around the periphery of the opening 20 and which project into the opening 20. The ridges 60 take up space within the opening 20 such that the open span of the opening 20 at the locations of the ridges 60 is less than the open span of the opening 20 at the locations without the ridges 60. The ridges 60 are configured to engage with an article 101, 301 inserted into the device to assist in securing it within the device 1. Open spaces (not shown in the Figures) defined by adjacent pairs of ridges 60 and the article 101, 301 form ventilation paths around the exterior of the article 101, 301. These ventilation paths allow hot vapours that have escaped from the article 101, 301 to exit the device 1 and allow cooling air to flow into the device 1 around the article 101 , 301 in the air gap 36.

In operation, the article 101, 301 is removably inserted into an insertion point 20 of the device 1, as shown in Figures 5 to 7. Referring particularly to Figure 6, in one example, the body of aerosol-generating composition 103, 303, which is located towards the distal end 115, 315 of the article 101, 301, is entirely received within the heater arrangement 23 of the device 1. The proximal end 113, 313 of the article 101, 301 extends from the device 1 and acts as a mouthpiece assembly for a user.

In operation, the heater arrangement 23 will heat the article 101, 301 to volatilise at least one component of the aerosol-generating composition from the body of aerosol-generating composition 103, 303. The primary flow path for the heated volatilised components from the body of aerosol-generating composition 103, 303 is axially through the article 101, 301, through the chamber inside the cooling segment 107, 307, through the filter segment 109, 309, through the mouth end segment 111, 313 to the user. In one example, the temperature of the heated volatilised components that are generated from the body of aerosol-generating composition is between 60°C and 250°C, which may be above the acceptable inhalation temperature for a user. As the heated volatilised component travels through the cooling segment 107, 307, it will cool and some volatilised components will condense on the inner surface of the cooling segment 107, 307. In the examples of the article 301 shown in Figures 3 and 4, cool air will be able to enter the cooling segment 307 via the ventilation holes 317 formed in the cooling segment 307. This cool air will mix with the heated volatilised components to provide additional cooling to the heated volatilised components. Another aspect of the invention provides a method of making an aerosol generating material according to the first aspect.

The method may comprise (a) forming a slurry comprising components of the aerosol-generating material or precursors thereof and a solvent (typically water), (b) forming a layer of the slurry, (c) optionally setting the slurry, and (d) drying the slurry to form an aerosol-generating material.

In some cases, less than or equal to about 15 wt% of the flavour added to the slurry is lost in steps (a)-(d), such as less than or equal to about 10 wt% or less than or equal to 5 wt% of the flavour added to the slurry.

In some cases, the dried aerosol-generating material retains at least about 85 wt% of the flavour added to the slurry, such as at least about 90% or at least about 95 % of the flavour added to the slurry. The amounts of components in the slurry can be determined based on the weights of the components added to the slurry. The amounts of menthol and glycerol in the dried aerosol-generating material can be measured by gas chromatography. Step (a) may comprise combining aerosol-generating agent, binder, flavour, filler, solvent (typically water) and any optional further components of the aerosol generating material to form the slurry.

Step (b) of forming a layer of the slurry may comprise spraying, casting or extruding the slurry, for example. In some cases, the slurry layer is formed by electrospraying the slurry. In some cases, the slurry layer is formed by casting the slurry.

In some cases, (b) and/or (c) and/or (d) may, at least partially, occur simultaneously (for example, during electrospraying). In some cases, (b), (c) and (d) may occur sequentially.

In some cases, the slurry is applied to a support. The layer may be formed on a support.

In examples, the slurry comprises binder, aerosol-generating agent, flavour and filler. The slurry may comprise these components on a dry weight basis in any of the proportions given herein in relation to the composition of the aerosol-generating material. For example, the slurry may comprise: aerosol-generating agent in an amount of from about 7 to about 13 wt% of the slurry; binder;

- flavour in an amount of from about 35 to about 50 wt% of the slurry; and - filler; wherein the above amounts are calculated on a dry weight basis. The slurry further comprises a solvent (typically water).

In one embodiment, the slurry comprises: - aerosol-generating agent in an amount of from about 7 to about 13 wt%; binder in an amount of from about 1 to about 57 wt%;

- flavour in an amount of from about 35 to about 50 wt%; and

- filler in an amount of from about 1 to about 50 wt%; wherein the above amounts are calculated on a dry weight basis. The slurry further comprises a solvent (typically water).

The setting step (c) may comprise the addition of a setting agent (also referred to as a crosslinking agent) to the slurry. Suitable setting/crosslinking agents and amounts thereof are set out above. For example, the slurry may comprise sodium, potassium or ammonium alginate as a gel-precursor, and a setting agent or crosslinking agent comprising a calcium source (such as calcium chloride, calcium acetate or calcium lactate), may be added to the slurry to form a calcium alginate gel.

In some embodiments the setting agent is applied by spraying the slurry with the setting agent.

The total amount of the setting agent/crosslinking agent, such as a calcium source, may be 0.5-7wt% (calculated on a dry weight basis). The addition of too little setting agent/crosslinking agent may result in an aerosol-generating material which does not stabilise the aerosol-generating material components and results in these components dropping out of the aerosol-generating material. The addition of too much setting agent or crosslinking agent may result in an aerosol-generating material that is very tacky and consequently has poor handleability. Alginate salts are derivatives of alginic acid and are typically high molecular weight polymers (10-600 kDa). Alginic acid is a copolymer of b-D-mannuronic (M) and a-L-guluronic acid (G) units (blocks) linked together with (1,4)-glycosidic bonds to form a polysaccharide. On addition of calcium cations, the alginate crosslinks to form a gel. Alginate salts with a high G monomer content more readily form a gel on addition of the calcium source. In some cases therefore, the gel-precursor may comprise an alginate salt in which at least about 40%, 45%, 50%, 55%, 60% or 70% of the monomer units in the alginate copolymer are a-L-guluronic acid (G) units. Setting the gel in step (c) may not be required, for example when the only binder present is a cellulosic binder such as CMC. When a non-cellulosic binder agent is present, such as alginate, the slurry may further comprise a setting agent or crosslinking agent and/or a setting agent or crosslinking agent may be applied to the slurry. In this case, the method may further comprise the step (c) of setting the slurry.

The drying step (d) may, in some cases, remove from about 50wt%, 60wt%, 70wt%, 80wt% or 90wt% to about 80wt%, 90wt% or 95wt% (WWB) of water in the slurry.

The drying step (d) may, in some cases, may reduce the cast material thickness by at least 80%, suitably 85% or 87%. For instance, the slurry may be cast at a thickness of 2mm, and the resulting dried aerosol-generating material may have a thickness of 0.2mm. During step (d) the slurry may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt% or 90 wt% of the solvent, which is typically water.

Following drying step (d), the aerosol-generating material may have a water content as defined above. In particular, the aerosol-generating material may have of from 1wt % to 15wt% (WWB). Suitably, the water content of the aerosol-generating material may be from about 5wt%, 7wt% or 9wt% to about 15wt%, 13wt% or 11wt% (wet weight basis) (WWB). The water content of the aerosol-generating material may, for example, be determined by Karl-Fischer-titration or Gas Chromatography with Thermal Conductivity Detector (GC-TCD). The aerosol-generating material, optionally in the form of a film, may be formed by combining the aerosol-generating agent, binder, flavour, filler, a solvent (typically water) and any optional further components to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the aerosol generating film. The slurry may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt% or 90 wt% of the solvent.

The slurry itself may also form part of the invention. In some cases, the slurry solvent may consist essentially of or consist of water. In some cases, the slurry may comprise from about 50wt%, 60wt%, 70wt%, 80wt% or 90wt% of solvent (WWB).

In cases where the solvent consists of water, the dry weight content of the slurry may match the dry weight content of the aerosol-generating material. Thus, the discussion herein relating to the solid material is explicitly disclosed in combination with the slurry aspect of the invention. In particular, aspects and embodiments above defining components of the aerosol-generating material and amounts thereof apply mutatis mutandis to the slurry of the invention and the method of the invention. In a further aspect, the invention also provides an aerosol-generating material obtainable by, or obtained by a method of the invention. Aspects and embodiments above defining components of the aerosol-generating material and amounts thereof apply mutatis mutandis to this further aspect of the invention. According to an aspect of the present invention there is provided a method of generating an aerosol using a non-combustible aerosol provision system as described herein. In some embodiments, the method comprises heating the aerosol generating material to a temperature of less than or equal to 350 °C. In some embodiments, the method comprises heating the aerosol-generating material to a temperature of from about 220 °C to about 280 °C. In some embodiments, the method comprises heating at least a portion of the aerosol-generating material to a temperature of from about 220 °C to about 280 °C over a session of use. “Session of use” as used herein refers to a single period of use of the non combustible aerosol provision system by a user. The session of use begins at the point at which power is first supplied to at least one heating unit present in the heating assembly. The device will be ready for use after a period of time has elapsed from the start of the session of use. The session of use ends at the point at which no power is supplied to any of the heating elements in the aerosol-generating device. The end of the session of use may coincide with the point at which the smoking article is depleted (the point at which the total particulate matter yield (mg) in each puff would be deemed unacceptably low by a user). The session will have a duration of a plurality of puffs. Said session may have a duration less than 7 minutes, or 6 minutes, or 5 minutes, or 4 minutes and 30 seconds, or 4 minutes, or 3 minutes and 30 seconds. In some embodiments, the session of use may have a duration of from 2 to 5 minutes, or from 3 to 4.5 minutes, or 3.5 to 4.5 minutes, or suitably 4 minutes. A session may be initiated by the user actuating a button or switch on the device, causing at least one heating element to begin rising in temperature.

All percentages by weight described herein (denoted wt%) are calculated on a dry weight basis (DWB), unless explicitly stated otherwise. All weight ratios are also calculated on a dry weight basis. A weight quoted on a dry weight basis refers to the whole of the slurry, aerosol-generating composition or aerosol-generating material, other than the water, and may include components which by themselves are liquid at room temperature and pressure, such as glycerol. Conversely, a weight percentage quoted on a wet weight basis (WWB) refers to all components, including water.

For the avoidance of doubt, where in this specification the term “comprises” is used in defining the invention or features of the invention, embodiments are also disclosed in which the invention or feature can be defined using the terms “consists essentially of” or “consists of” in place of “comprises”. Reference to a material “comprising” certain features means that those features are included in, contained in, or held within the material.

Any feature described in relation to one aspect of the invention is expressly disclosed in combination with any other aspect described herein. Exemplary Embodiments

Further embodiments of the invention are as follows:

1. An aerosol-generating material comprising: aerosol-generating agent in an amount of from about 7 to about 13 wt% of the aerosol-generating material on a dry weight basis; binder;

- filler.

2. The aerosol-generating material of Embodiment 1, wherein the flavour comprises menthol.

3. The aerosol-generating material of Embodiment 2, wherein the flavour consists of menthol.

4. The aerosol-generating material of any preceding Embodiment, wherein the aerosol-generating agent comprises one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

5. The aerosol-generating material of Embodiment 4, wherein the aerosol generating agent consists of one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

6. The aerosol-generating material of any preceding Embodiment, wherein the aerosol-generating agent comprises glycerol.

7. The aerosol-generating material of Embodiment 6, wherein the aerosol generating agent consists of glycerol. 8. The aerosol-generating material according to any preceding Embodiment, wherein the aerosol-generating material comprises aerosol-generating agent in an amount of 8-13 wt% (on a dry weight basis).

9. The aerosol-generating material according to any preceding Embodiment, wherein the aerosol-generating material comprises aerosol-generating agent in an amount of 9-12wt% (on a dry weight basis).

10. The aerosol-generating material according to any preceding Embodiment, wherein the aerosol-generating material comprises aerosol-generating agent in an amount of 10-12wt% (on a dry weight basis).

11. The aerosol-generating material according to any preceding Embodiment, wherein the aerosol-generating material comprises aerosol-generating agent in an amount of more than 10wt% to less than 12 wt% (on a dry weight basis).

12. The aerosol-generating material according to any preceding Embodiment, wherein the aerosol-generating material comprises aerosol-generating agent in an amount of 10.3-11.9wt% (on a dry weight basis).

13. The aerosol-generating material according to any preceding Embodiment, wherein the aerosol-generating material comprises flavour in an amount of

35-45 wt% (on a dry weight basis).

14. The aerosol-generating material according to any preceding Embodiment, wherein the aerosol-generating material comprises flavour in an amount of

36-45wt% (on a dry weight basis).

15. The aerosol-generating material according to any preceding Embodiment, wherein the aerosol-generating material comprises flavour in an amount of

37-43wt% (on a dry weight basis).

16. The aerosol-generating material according to any preceding Embodiment, wherein the binder comprises alginate and/or pectin.

17. The aerosol-generating material according to any preceding Embodiment, wherein the binder comprises alginate and pectin.

18. The aerosol-generating material according to any of Embodiments 1-16, wherein the binder consists of alginate and/or pectin.

19. The aerosol-generating material according to any preceding Embodiment, wherein the binder consists of alginate and pectin. 20. The aerosol-generating material according to any preceding Embodiment, wherein the aerosol-generating material is substantially free of cellulosic binder.

21. The aerosol-generating material according to any preceding Embodiment, , wherein the aerosol-generating material is substantially free of carboxymethylcellulose.

21a. The aerosol-generating material according to any of Embodiments 1-17, wherein the binder comprises a cellulosic binder and a non-cellulosic binder.

21b. The aerosol-generating material according to Embodiment 21a, wherein the cellulosic binder comprises, consists essentially of, or consists of, carboxymethyl cellulose.

21c. The aerosol-generating material according to Embodiment 21a or 21b, wherein the non-cellulosic binder comprises, consists essentially of, or consists of, alginate and/or guar gum. 21d. The aerosol-generating material according to Embodiment 21c, wherein the non-cellulosic binder comprises, consists essentially of, or consists of, alginate and guar gum.

21e. The aerosol-generating material according to any of Embodiments 21a-21d, wherein the binder comprises, consists essentially of, or consists of CMC, alginate and guar gum.

22. The aerosol-generating material according to any preceding Embodiment, wherein the aerosol-generating material comprises binder in an amount of 1-57wt% (on a dry weight basis).

23. The aerosol-generating material according to any preceding Embodiment, wherein the aerosol-generating material comprises binder in an amount of

5-50wt% (on a dry weight basis).

24. The aerosol-generating material according to any preceding Embodiment, wherein the aerosol-generating material comprises binder in an amount of 15-35wt% (on a dry weight basis). 25. The aerosol-generating material according to any preceding Embodiment, wherein the aerosol-generating material comprises binder in an amount of 20-30wt% (on a dry weight basis). 26. The aerosol-generating material according to any preceding Embodiment, wherein the aerosol-generating material comprises binder in an amount of 20-25wt% (on a dry weight basis).

27. The aerosol-generating material according to any preceding Embodiment, wherein the filler comprises wood pulp.

28. The aerosol-generating material according to any preceding Embodiment, wherein the filler consists of wood pulp.

29. The aerosol-generating material according to any preceding Embodiment, wherein the aerosol-generating material comprises filler in an amount of 5-45wt% (on a dry weight basis).

30. The aerosol-generating material according to any preceding Embodiment, wherein the aerosol-generating material comprises filler in an amount of such as 10-40wt% (on a dry weight basis).

31. The aerosol-generating material according to any preceding Embodiment, wherein the aerosol-generating material comprises filler in an amount of 18-

35wt% (on a dry weight basis).

32. The aerosol-generating material according to any preceding Embodiment, wherein the aerosol-generating material comprises filler in an amount of 20-30wt% (on a dry weight basis). 33. The aerosol-generating material according to any preceding Embodiment, wherein the aerosol-generating material further comprises a crosslinking agent.

34. The aerosol-generating material according to Embodiment 33, wherein the crosslinking agent comprises calcium ions 35. The aerosol-generating material according to Embodiment 34, wherein crosslinking agent comprises calcium lactate and/or calcium acetate.

36. The aerosol-generating material according to Embodiment 35, wherein crosslinking agent consists of calcium lactate and/or calcium acetate.

36a. The aerosol-generating material according to any preceding Embodiment, wherein the aerosol-generating material comprises 1-10 wt% of crosslinking agent (dry weight basis).

36b. The aerosol-generating material according to any preceding Embodiment, wherein the aerosol-generating material comprises 3-8 wt% of crosslinking agent

(dry weight basis). 36c. The aerosol-generating material according to any preceding Embodiment, wherein the aerosol-generating material comprises 5-7 wt% of crosslinking agent

(dry weight basis).

37. The aerosol-generating material according to any preceding Embodiment, wherein the aerosol-generating material is substantially free from tobacco.

38. The aerosol-generating material according to any preceding Embodiment, wherein the aerosol-generating material is in the form of a sheet.

39. The aerosol-generating material according to any preceding Embodiment, aerosol-generating material is in the form of a film on a support. 40. An aerosol-generating composition comprising the aerosol-generating material of any of Embodiments 1-39.

41. An aerosol-generating composition consisting essentially of the aerosol generating material of Embodiments 1-39.

42. An aerosol-generating composition consisting of the aerosol-generating material of any of Embodiments 1-39.

43. A consumable for use with a non-combustible aerosol provision device, the consumable comprising the aerosol-generating composition according to any of Embodiments 40-42 or the aerosol-generating material of any of Embodiments 1-39. 44. A non-combustible aerosol provision system comprising the consumable according to Embodiment 43 and a non-combustible aerosol provision device, wherein the non-combustible aerosol provision device is configured to generate aerosol from the consumable when the consumable is used with the non-combustible aerosol provision device. 45. The system according to Embodiment 44 wherein the non-combustible aerosol provision device comprises a heater configured to heat but not burn the consumable.

46. Use of the aerosol-generating material of any of Embodiments 1-39 or an aerosol-generating composition of any of Embodiments 41-43 for generating an aerosol.

S1. A slurry comprising: aerosol-generating agent in an amount of from about 7 to about 13 wt% of the slurry on a dry weight basis; binder; flavour in an amount of from about 35 to about 50 wt% of the slurry on a dry weight basis; filler; and - a solvent.

52. The slurry of Embodiment S1 , wherein the flavour comprises menthol.

53. The slurry of Embodiment S2, wherein the flavour consists of menthol.

54. The slurry of any preceding Embodiment, wherein the aerosol-generating agent comprises one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1 ,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

55. The slurry of Embodiment S4, wherein the aerosol-generating agent consists of one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. S6. The slurry of any preceding Embodiment, wherein the aerosol-generating agent comprises glycerol.

57. The slurry of Embodiment S6, wherein the aerosol-generating agent consists of glycerol.

58. The slurry according to any preceding Embodiment, wherein the slurry comprises aerosol-generating agent in an amount of 8-13 wt% (on a dry weight basis).

59. The slurry according to any preceding Embodiment, wherein the slurry comprises aerosol-generating agent in an amount of 9-12wt% (on a dry weight basis).

510. The slurry according to any preceding Embodiment, wherein the slurry comprises aerosol-generating agent in an amount of 10-12wt% (on a dry weight basis).

511. The slurry according to any preceding Embodiment, wherein the slurry comprises aerosol-generating agent in an amount of more than 10wt% to less than 12 wt% (on a dry weight basis). 512. The slurry according to any preceding Embodiment, wherein the slurry comprises aerosol-generating agent in an amount of 10.3-11.9wt% (on a dry weight basis).

513. The slurry according to any preceding Embodiment, wherein the slurry comprises flavour in an amount of 35-45 wt% (on a dry weight basis).

514. The slurry according to any preceding Embodiment, wherein the slurry comprises flavour in an amount of 36-45wt% (on a dry weight basis).

515. The slurry according to any preceding Embodiment, wherein the slurry comprises flavour in an amount of 37-43wt% (on a dry weight basis). S16. The slurry according to any preceding Embodiment, wherein the binder comprises alginate and/or pectin.

517. The slurry according to any preceding Embodiment, wherein the binder comprises alginate and pectin.

518. The slurry according to any of Embodiments S1-S16, wherein the binder consists of alginate and/or pectin.

519. The slurry according to any preceding Embodiment, wherein the binder consists of alginate and pectin.

520. The slurry according to any preceding Embodiment, wherein the slurry is substantially free of cellulosic binder. S21. The slurry according to any preceding Embodiment, , wherein the slurry is substantially free of carboxymethylcellulose.

522. The slurry according to any preceding Embodiment, wherein the slurry comprises binder in an amount of 1-57wt% (on a dry weight basis).

523. The slurry according to any preceding Embodiment, wherein the slurry comprises binder in an amount of 5-50wt% (on a dry weight basis).

524. The slurry according to any preceding Embodiment, wherein the slurry comprises binder in an amount of 15-35wt% (on a dry weight basis).

525. The slurry according to any preceding Embodiment, wherein the slurry comprises binder in an amount of 20-30wt% (on a dry weight basis). S26. The slurry according to any preceding Embodiment, wherein the slurry comprises binder in an amount of 20-25wt% (on a dry weight basis).

S27. The slurry according to any preceding Embodiment, wherein the filler comprises wood pulp. 528. The slurry according to any preceding Embodiment, wherein the filler consists of wood pulp.

529. The slurry according to any preceding Embodiment, wherein the slurry comprises filler in an amount of 5-45wt% (on a dry weight basis). S30. The slurry according to any preceding Embodiment, wherein the slurry comprises filler in an amount of such as 10-40wt% (on a dry weight basis).

531. The slurry according to any preceding Embodiment, wherein the slurry comprises filler in an amount of 18-35wt% (on a dry weight basis).

532. The slurry according to any preceding Embodiment, wherein the slurry comprises filler in an amount of 20-30wt% (on a dry weight basis).

533. The slurry according to any preceding Embodiment, wherein the slurry further comprises a crosslinking agent.

534. The slurry according to Embodiment S33, wherein the crosslinking agent comprises calcium ions S35. The slurry according to Embodiment S34, wherein crosslinking agent comprises calcium lactate and/or calcium acetate.

S36. The slurry according to Embodiment S35, wherein crosslinking agent consists of calcium lactate and/or calcium acetate.

S36a. The slurry according to any preceding Embodiment, wherein the slurry comprises 1-10 wt% of crosslinking agent (dry weight basis).

S36b. The slurry according to any preceding Embodiment, wherein the slurry comprises 3-8 wt% of crosslinking agent (dry weight basis).

S36c. The slurry according to any preceding Embodiment, wherein the slurry comprises 5-7 wt% of crosslinking agent (dry weight basis). S37. The slurry according to any preceding Embodiment, wherein the slurry is substantially free from tobacco.

538. The slurry according to any preceding Embodiment, wherein the solvent comprises water.

539. The slurry according to any preceding Embodiment, wherein the solvent is water.

Embodiment 47. A method of making an aerosol-generating material the method comprising:

(a) forming a slurry according to any of Embodiments S1-S39 (b) forming a layer of the slurry;

(c) optionally setting the slurry; and

(d) drying the slurry to form the aerosol-generating material.

Embodiment 48. The method of Embodiment 47, wherein the aerosol- generating material is the aerosol-generating material of any of Embodiments 1-39. Embodiment 49. The method of Embodiment 47 or 48, wherein less than or equal to about 15 wt% of the flavour added to the slurry is lost in steps (a)-(d). Embodiment 50. The method of Embodiment 49, wherein less than or equal to about 10 wt% of the flavour added to the slurry is lost in steps (a)-(d). Embodiment 51. The method of Embodiment 50, wherein less than or equal to

5 wt% of the flavour added to the slurry is lost in steps (a)-(d).

Embodiment 52. An aerosol-generating material obtainable by the method of any of Embodiments 47-51.

Embodiment 53. An aerosol-generating material obtained by the method of any of Embodiments 47-51.

Examples

Gas chromatography measurement method REAGENTS

A1.1 Solvent: Methanol - (HPLC Grade or similar)

A1.2 Internal standard (ISTD): n-Heptadecane or Anethole (purity > 99.0%)

A1.3 Reference substances: menthol - (purity > 99.0%)

A1.4 Carrier gas: helium of high purity (at least 99,995%) A1.5 Auxiliary gases: air for flame ionisation detector (FID), hydrogen of high purity

(at least 99,995%) for the FID,

A1.6 Other reagents: Ultrapure water

A1.7 Extraction solution: extraction solvent (A1.1) containing the internal standard (A1.2) A1.8.1 Extraction Solution

Weigh (2.5 ± 0.01) g of n-heptadecane (ISTD) into a weighing vessel and add to the 5 L volumetric flask, containing 400-500 ml_ of methanol. Mix thoroughly to dissolve the n-heptadecane overnight. When dissolved make up to the correct volume with methanol. A1.8.2 Calibration Stock Solution (SA)

Weigh accurately approximately (8.0 ± 0.01) g menthol directly into a 200-mL volumetric flask. Rinse the weighing vessel with extraction solution, into the volumetric flask, after each compound has been weighed. Fill up to volume with extraction solution and mix the flask contents by repeated inversion of the flask.

APPARATUS

• Gas Chromatograph equipped with a split/splitless injection system, one analytical column, flame ionisation (FID) detector and data analysis system.

• GC Column: Phenomenex ZB-WAXplus (or equivalent); 30 m x 0.53 mm id x 1.00 pm

• Analytical Balance (precision 0.1 mg)

• Volumetric Glassware

• Stoppered 150 mL conical flasks

• Amber Vials with lids to store the solutions in the refrigerator (60 mL and 40 mL)

• GC vials and caps

• Crimping Tool • Magnetic Stirrer

• Orbital/Horizontal flask shaker

• Glass Pipettes - grade A PROCEDURE

A calibration graph was constructed for menthol analyte by diluting calibration stock solution (A1.8.2) to provide a range of calibration standards and analysing the calibration standards by gas chromatography.

Dried aerosol-generating materials were extracted according to the following procedure. The extracts were then analysed by gas chromatography. Peak areas were used as a measure of analyte concentration.

• Weigh 0.25 g of the dried aerosol-generating material sample into a 150-mL conical flask

• Add 50 ml_ of Extraction Solution with a calibrated dispenser.

• Stopper the flask.

• Set shaking on an Orbital/Horizontal shaker for 3 hours at 150 rpm.

• Using a plastic 5 ml_ syringe, filter some extract through a 0.45 pm PTFE filter into a 2 ml_ amber GC Vial.

• Crimp the vial and label.

Column Parameters

Inlet/Injector Parameters

Detector Parameters

Oven parameters

To enable conversion of concentrations to dry weight basis, water concentrations of the aerosol generating materials were also measured by Karl Fischer titration.

Example 1 (reference) Reference aerosol-generating materials were produced by forming a slurry comprising water, menthol, glycerol, alginate, pectin, and wood pulp, casting the slurry, applying calcium lactate onto the cast slurry and drying the slurry. The amounts of the constituents added to the slurry were as follows (all on a dry weight basis):

The amount of menthol in the dried aerosol-generating material was then measured using gas chromatography according to the procedure outlined above. Across 45 samples, the mean amount of menthol measured in the dried material was about 28.5 wt% (compared to 40 wt% in the initial slurry). The samples therefore showed significant menthol loss (about 29% loss) during the production process.

Example 2

Aerosol-generating materials according to the invention were produced by forming a slurry comprising water, menthol, glycerol, alginate, pectin, and wood pulp, casting the slurry, applying calcium lactate onto the cast slurry (in the same amount as in Example 1) and drying the slurry. The amounts of menthol and glycerol in the aerosol-generating materials were then measured using gas chromatography according to the procedure outlined above. The amounts of the constituents added to the slurry were as follows (all on a dry weight basis): The amount of menthol in the dried aerosol-generating material was then measured for two different samples of the composition, and found to be 39.85 wt% (sample 1) and 38.74 wt% (sample 2). The samples therefore showed less than 5% menthol loss during the production process.

As can be seen from this Example, reducing the amount of glycerol unexpectedly reduced menthol loss from the aerosol-generating material compared to reference Example 1.

Claims

1. An aerosol-generating material comprising:

- from about 7 to about 13 wt% aerosol-generating agent; binder;

- from about 35 to about 50 wt% flavour; and

- filler.

2. The aerosol-generating material according to claim 1, comprising:

- from about 7 to about 13 wt% aerosol-generating agent;

- from about 1 to about 57 wt% binder;

- from about 35 to about 50 wt% flavour; and

- from about 1 to about 50 wt% filler; wherein these amounts are calculated on a dry weight basis.

3. The aerosol-generating material according to claim 1 or claim 2, wherein the flavour comprises menthol.

4. The aerosol-generating material according to any preceding claim, wherein the aerosol-generating agent comprises one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

5. The aerosol-generating material according to any preceding claim, wherein the aerosol-generating agent comprises glycerol.

6. The aerosol-generating material according to any preceding claim, wherein the aerosol-generating material comprises aerosol-generating agent in an amount of from about 8 to about 13 wt%.

7. The aerosol-generating material according to any preceding claim, wherein the aerosol-generating material comprises flavour in an amount of from about 35 to about 45 wt%.

8. The aerosol-generating material according to any preceding claim, wherein the binder comprises alginate and/or pectin.

9. The aerosol-generating material according to any preceding claim, wherein the aerosol-generating material is substantially free of cellulosic binder.

10. The aerosol-generating material according to any preceding claim, wherein the aerosol-generating material is substantially free of carboxymethylcellulose.

11. The aerosol-generating material according to any of claims 1-8, wherein the binder comprises cellulosic binder and non-cellulosic binder.

12. The aerosol-generating material according to claim 11 , wherein the cellulosic binder comprises carboxymethyl cellulose; and/or wherein the non-cellulosic binder comprises alginate and/or guar gum.

13. The aerosol-generating material according to any preceding claim, wherein the aerosol-generating material comprises binder in an amount of from about 1 to about 57wt%.

14. The aerosol-generating material according to any preceding claim, wherein the filler comprises wood pulp.

15. The aerosol-generating material according to any preceding claim, wherein the aerosol-generating material comprises filler in an amount of from about 5 to about 45wt%.

16. The aerosol-generating material according to any preceding claim, wherein the aerosol-generating material further comprises a crosslinking agent.

17. The aerosol-generating material according to claim 16, wherein the crosslinking agent comprises calcium ions, such as wherein the crosslinking agent comprises calcium lactate and/or calcium acetate.

18. The aerosol-generating material according to any preceding claim, wherein the aerosol-generating material is substantially free from tobacco.

19. An aerosol-generating composition comprising the aerosol-generating material of any of any preceding claim.

20. A consumable for use with a non-combustible aerosol provision device, the consumable comprising the aerosol-generating composition according to claim 19.

21. A non-combustible aerosol provision system comprising the consumable according to claim 20 and a non-combustible aerosol provision device, wherein the non-combustible aerosol provision device is configured to generate aerosol from the consumable when the consumable is used with the non-combustible aerosol provision device.

22. The system according to claim 21 wherein the non-combustible aerosol provision device comprises a heater configured to heat but not burn the consumable.

23. Use of the aerosol-generating material of any one of claims 1-18 or an aerosol-generating composition of claim 19 for generating an aerosol.

24. A slurry comprising:

- from about 7 to about 13 wt% aerosol-generating agent; binder;

- from about 35 to about 50 wt% flavour; and

- filler; wherein these weights are calculated on a dry weight basis, and a solvent.

25. A method of making an aerosol-generating material, the method comprising:

(a) forming a slurry comprising

- from about 7 to about 13 wt% aerosol-generating agent; binder;

- from about 35 to about 50 wt% flavour; and - filler; wherein these weights are calculated on a dry weight basis, and a solvent;

(b) forming a layer of the slurry;

(c) optionally setting the slurry; and (d) drying the slurry to form the aerosol-generating material.

26. The method according to claim 25, wherein less than or equal to about 15 wt% of the flavour added to the slurry is lost in steps (a)-(d), such as less than or equal to about 10 wt% or less than or equal to 5 wt% of the flavour added to the slurry.

27. A slurry according to claim 24 or the method according to claim 25 or 26, wherein the solvent is water. 28. An aerosol-generating material obtainable by the method of any of claims 25-

27.