CN114466598A

CN114466598A - Aerosol generation

Info

Publication number: CN114466598A
Application number: CN202080054969.0A
Authority: CN
Inventors: 路德维格·弗里德里克
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2019-07-31
Filing date: 2020-07-31
Publication date: 2022-05-10
Also published as: JP2022542897A; WO2021019072A3; IL289888A; AU2020320037A1; GB201910952D0; EP4003064A2; US20220248743A1; WO2021019072A2; CA3148884A1; KR20220040458A; AU2020320037B2; AU2024201017A1; BR112022001565A2

Abstract

Disclosed herein is an aerosol-generating article (101, 301) for an aerosol-generating component, the article comprising an aerosol-generating substrate comprising an aerosol-generating material (103, 303), wherein the aerosol-generating material is a solid and comprises starch and a plasticiser, wherein the amount of plasticiser is from about 5% to 70% by weight of the starch.

Description

Aerosol generation

Technical Field

The present invention relates to aerosol generation.

Background

Smoking articles such as cigarettes, cigars and the like burn tobacco during use to produce tobacco smoke. Alternatives to these types of articles release inhalable aerosols or vapors by heat without burning the release compound from the base material. These may be referred to as non-combustible smoking articles or aerosol-generating components.

One example of such a product is a heating device that releases a compound by heating without burning solid aerosolisable material. In some cases, such solid aerosolizable material can comprise a tobacco material. This heating volatilizes at least one component of the material, typically forming an inhalable aerosol. These products may be referred to as heated non-combustion devices, tobacco heating devices, or tobacco heating products. Various different devices for volatilizing at least one component of a solid aerosolizable material are known.

Another known type of aerosol-generating component is an electronic cigarette or e-cigarette. In these devices, the liquid or gel aerosol generating material is heated without combusting. This causes one component of the material to vaporize to form an inhalable vapor or aerosol. The liquid or gel material may comprise nicotine.

As another example, there is an electronic cigarette/tobacco heating product mixing device, also known as an electronic tobacco mixing device. These mixing devices contain a liquid source (which may or may not contain nicotine) that is vaporized by heating to produce an inhalable vapor or aerosol. The device additionally comprises a solid aerosolizable material (which may or may not comprise a tobacco material), and components of this material are entrained in an inhalable vapor or aerosol to produce an inhalation medium.

Disclosure of Invention

A first aspect of the invention provides an aerosol-generating article for an aerosol-generating component, the article comprising an aerosol-generating substrate comprising an aerosol-generating material, wherein the aerosol-generating material is solid and comprises starch and a plasticiser, wherein the amount of plasticiser is from about 5% to 70% by weight of the starch.

A second aspect of the invention provides an aerosol-generating assembly comprising an aerosol-generating article according to the first aspect and a heater configured to heat, but not burn, an aerosol-generating material.

A third aspect of the invention provides a starch substrate material comprising;

-a plasticizer, wherein the amount of plasticizer is about 5% to 70% by weight of the starch; and

-a flavour or fragrance ingredient of vegetable origin.

A fourth aspect of the invention is a kit comprising an aerosol-generating article according to the first aspect and a device configured to receive the article in use, the device comprising a heater configured to heat, in use, but not burn, the aerosol-generating material.

A fifth aspect of the invention provides a method of manufacturing an aerosol-generating article according to the first aspect, the method comprising;

(i) mixing the components of the aerosol-generating material in a slurry, heating and stirring the slurry to effect gelation, casting the gel and drying by heating to form the aerosol-generating material; and

(ii) an aerosol-generating material is incorporated into an aerosol-generating article.

The present invention also provides a slurry comprising:

-a starch;

-a flavour or fragrance ingredient of vegetable origin; and

-water.

Suitably, the weight ratio of water to the total weight of the other components is between about 10:1 and 20: 1.

The present invention also provides a slurry comprising:

-a starch;

-a plasticizer, wherein the amount of plasticizer is about 5% to 70% by weight of the starch;

-a powdered tobacco material having an average particle size of less than about 250 μm, wherein the amount of powdered tobacco material is about 40% to 300% by weight of the starch;

-water, wherein the weight ratio of water to the total weight of the other components is between about 10:1 and 20: 1.

The present invention also provides a slurry comprising:

-a starch;

-an aqueous tobacco extract, wherein the weight ratio of the aqueous tobacco extract to the total weight of the other components is between about 10:1 and 20: 1.

Other aspects of the invention include:

(i) a wrapper for a smoking article or an aerosol-generating article, wherein the wrapper comprises a starch substrate and a plasticiser, wherein the amount of plasticiser is from about 5% to 30% by weight of the starch; and

(ii) a filter for a smoking article or an aerosol-generating article, the filter comprising a starch substrate and a plasticiser, wherein the amount of plasticiser is from about 5% to 15% by weight of the starch.

The present invention also provides an article comprising the wrapper and/or filter described above.

Other aspects, features and advantages of the present invention will become apparent from the following description, given by way of example only, and with reference to the accompanying drawings. Features described herein in relation to one aspect are expressly disclosed in connection with other aspects of the invention to the extent they are compatible.

Drawings

Figure 1 shows a cross-sectional view of an example of an aerosol-generating article.

Fig. 2 shows a perspective view of the article of fig. 1.

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

Fig. 4 shows a perspective view of the article of fig. 3.

Figure 5 shows a perspective view of an example of an aerosol-generating assembly.

Figure 6 shows a cross-sectional view of an example of an aerosol-generating assembly.

Figure 7 shows a perspective view of an example of an aerosol-generating assembly.

Detailed Description

The aerosol-generating material described herein is a "solid". However, it may be a solid that retains some fluid (e.g., liquid) within its interior. The solid may be a gel. It may be referred to as a "dry gel". It may also be referred to as a "starch matrix".

As mentioned above, the present invention provides an aerosol-generating article for an aerosol-generating component, the article comprising an aerosol-generating substrate comprising an aerosol-generating material, wherein the aerosol-generating material is solid and comprises starch and a plasticiser, wherein the amount of plasticiser is from about 5% to 70% by weight of the starch.

The inventors have found that a material having such a composition can be heated efficiently to generate an inhalable aerosol.

Starch forms a helix structure and small molecules such as flavors and fragrances can be incorporated within this helix. However, the release of these molecules requires heating the helix to unwind it. The aerosol-generating material described herein is formed by heating and dissolving starch and mixing with a plasticiser. The plasticizer is embedded in the starch. Then as the starch cools, retrogradation (rearrangement to a crystalline helical form) is inhibited by glycerol, producing an irregular starch matrix to which small molecules can bind. The release temperature of these small molecules is lower than that of the regular crystal structure.

The present inventors have determined that such starch substrate materials (including plasticizers within the scope of the claimed invention) are suitable for use as aerosol generating materials in non-combustible smoking articles.

Any starch may be used in the present invention. Suitably, the starch may be a soluble starch, suitably an unmodified soluble starch. Suitably, the starch may be derived from a gluten-free product. The starch may comprise potato starch. Such materials are readily available. The present inventors have determined that the use of starch as a matrix material is preferred over other materials such as alginate and pectin, as these other ingredients require the addition of a setting agent (e.g. a calcium source) to form the matrix; starch does not require such additional agents. Alginates and pectins also produce off-flavours to the flavour/aroma of the aerosol produced and it has been found that the use of starch as a matrix material reduces this effect. Starch also has a higher loading capacity. Starch materials are also generally less viscous than comparable alginate or pectin materials, and thus easier to manufacture and handle.

The amount of plasticizer is about 5% to 70% by weight of the starch. Suitably, the amount of plasticizer may be from about 5%, 10%, 15% or 20% to about 70%, 60% or 50% by weight of the starch. If the plasticizer content is too low, the resulting matrix may be brittle and/or the starch helical structure may be relatively ordered, meaning that any small molecules incorporated in the helix may be difficult to release in use. Conversely, if the plasticizer content is too high, the resulting matrix may be tacky and difficult to handle, and/or the matrix may be disordered such that any bound small molecules are too easily released in use. Furthermore, if the content of plasticizer is too high, the material may absorb water (because the plasticizer is hygroscopic), resulting in a material that does not produce a suitable consumer experience in use.

Furthermore, the plasticizer content specified herein provides the aerosol-generating material with flexibility that allows for the winding of a sheet of material onto a bobbin, which is useful in the manufacture of aerosol-generating articles.

In some cases, the plasticizer may be an aerosol generating agent. Suitably, the plasticiser comprises one or more compounds selected from erythritol, sorbitol, glycerol, glycols (e.g. propylene glycol), monohydric alcohols, high boiling hydrocarbons, lactic acid, glycerol diacetate, glycerol triacetate, triethylene glycol diacetate, triethyl citrate, ethyl myristate, isopropyl myristate, methyl stearate, dimethyl dodecanedioate and dimethyl tetradecanedioate. Suitably, the plasticiser may comprise one or more of erythritol, propylene glycol, glycerol, glyceryl triacetate, sorbitol and xylitol. In some cases, the aerosol-generating agent comprises, consists essentially of, or consists of glycerol.

In some cases, the aerosol-generating material may be a hydrogel and comprise less than about 20 wt%, 15 wt%, 12 wt% or 10 wt% water, calculated on a Wet Weight Basis (WWB). In some cases, the material may include at least about 1 wt%, 2 wt%, or 5 wt% water (WWB). In some cases, the amorphous solid comprises from about 1 wt% to about 15 wt% water, or from about 5 wt% to about 15 wt% water, based on wet weight. Suitably, the water content of the amorphous solid may be from about 5 wt%, 7 wt% or 9 wt% to about 15 wt%, 13 wt% or 11 wt% (WWB), most suitably about 10 wt%. This water level ensures that the material is relatively resistant to microbial degradation (e.g., mold growth).

The aerosol-generating material may also comprise flavour or aroma components of plant origin. In some cases, this may be a powdered plant-derived ingredient, and may have a particle size of less than about 250 μm, suitably less than about 200 μm or 150 μm (i.e. the powder has been sieved and passed through a sieve having this pore size). In some cases, the average particle size of the powder may be less than about 250 μm, suitably less than about 200 μm or 150 μm. The present inventors have found that if the powder is incorporated into a matrix structure, it is desirable to have a specified particle size-larger particle sizes disrupt the starch matrix and any incorporated small molecules are too easily released upon use.

The amount of powder ingredient may suitably be from about 40% to about 300% by weight of the starch, more suitably from about 50% to about 200% or 100% by weight of the starch.

In some cases, the amorphous solid comprises an active. For example, in some cases, the amorphous solid comprises tobacco material and/or nicotine. For example, the amorphous solid may additionally comprise powdered tobacco (having a particle size (or average diameter) as described above) and/or nicotine and/or a tobacco extract. In this case, the nicotine and/or tobacco flavor/taste components of the extract may be bound to the starch. In some cases, an amorphous solid can include from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 80 wt%, 70 wt%, 50 wt%, 45 wt%, or 40 wt% (by dry weight) of active. In some cases, the amorphous solid can include about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 80 wt%, 70 wt%, 60 wt%, 50 wt%, 45 wt%, or 40 wt% (by dry weight) of tobacco material and/or nicotine.

In some cases, the amorphous solid comprises an active substance, such as a tobacco extract. In some cases, the amorphous solids can include 5-60 wt% (dry weight basis) of the tobacco extract. In some cases, the amorphous solid can include about 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 55 wt%, 50 wt%, 45 wt%, or 40 wt% (on a dry weight basis) of the tobacco extract. For example, the amorphous solid may comprise 5-60 wt%, 10-55 wt%, or 25-55 wt% of the tobacco extract. The tobacco extract can comprise nicotine at a concentration such that the amorphous solid comprises from 1 wt%, 1.5 wt%, 2 wt%, or 2.5 wt% to about 6 wt%, 5 wt%, 4.5 wt%, or 4 wt% (on a dry weight basis) nicotine. In some cases, the amorphous solid may be free of nicotine other than nicotine produced by the tobacco extract.

Where the amorphous solid comprises a tobacco extract, it may be an aqueous extract obtained by extraction with water. In some cases, the tobacco extract may act as a solvent within the plasticizer (i.e., obtained by extraction using the plasticizer). The tobacco extract may be an extract from any suitable tobacco, such as a single grade or mixture, cut or whole leaf, including virginia and/or burley and/or oriental tobaccos. It may also be an extract from tobacco particulate "fines" or dust, expanded tobacco, stems, expanded stems, and other processed stem materials (e.g., cut rolled stems). The extract may be obtained from ground tobacco or reconstituted tobacco material.

In some cases, the aerosol-generating material may comprise a perfume. In some cases, the flavoring agent (if present) comprises, consists essentially of, or consists of menthol. Suitably, the amorphous solid may comprise up to about 60 wt%, 50 wt%, 40 wt%, 30 wt%, 20 wt%, 10 wt% or 5 wt% flavouring agent. In some cases, the amorphous solid can include at least about 0.5 wt%, 1 wt%, 2 wt%, 5 wt%, 10 wt%, 20 wt%, or 30 wt% flavoring (all calculated on a dry weight basis). For example, the amorphous solid may include 0.1 to 60 wt%, 1 to 60 wt%, 5 to 60 wt%, 10 to 60 wt%, 20 to 50 wt%, or 30 to 40 wt% of the flavoring agent. In some cases, the flavoring agent (if present) comprises, consists essentially of, or consists of menthol. In some cases, the amorphous solid does not include a flavoring agent.

In some embodiments, the amorphous solid comprises less than 60 wt% filler, for example, 1 wt% to 60 wt%, or 5 wt% to 50 wt%, or 5 wt% to 30 wt%, or 10 wt% to 20 wt%.

In other embodiments, the amorphous solid comprises less than 20 wt%, suitably less than 10 wt% or less than 5 wt% filler. In some cases, the amorphous solid includes less than 1 wt% filler, and in some cases, no filler. In some embodiments, the amorphous solid does not include tobacco fiber. In particular embodiments, the amorphous solid does not include fibrous material.

If present, the filler may include one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents, such as molecular sieves. The filler may comprise one or more organic filler materials such as wood pulp, cellulose and cellulose derivatives. In particular instances, the amorphous solid does not include calcium carbonate, such as chalk.

In particular embodiments that include a filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material, such as wood pulp, cellulose or cellulose derivatives. Without wishing to be bound by theory, it is believed that the inclusion of fibrous fillers in the amorphous solid may increase the tensile strength of the material. This may be particularly advantageous in instances where the amorphous solid is provided in sheet form, for example when the amorphous solid sheet circumscribes a rod of aerosolizable material.

In some cases, the aerosol-generating material may consist essentially of, or consist of, starch, a plasticizer, water, and optionally a plant-derived flavor or fragrance ingredient, and optionally a flavorant. In some cases, the aerosol-generating material may consist essentially of, or consist of, potato starch, glycerin, tobacco material, and water.

In some cases, the aerosol-generating substrate may additionally comprise a carrier on which the solids of aerosol-generating material are disposed. Such a carrier may be easy to manufacture and/or handle, for example by (a) providing a surface onto which the slurry can be cast (and the slurry need not be separated from the latter), (b) providing a non-tacky surface for the aerosol-generating substrate for ease of handling, (c) providing some rigidity to the substrate.

In some cases, the support may be formed from a material selected from the group consisting of metal foil, paper, carbon paper, greaseproof paper, ceramic, carbon allotropes (e.g., graphite and graphene), plastic, cardboard, wood, or a combination thereof. In some cases, the carrier may comprise or consist of a tobacco material, such as a sheet of reconstituted tobacco. In some cases, the carrier may be formed from a material selected from the group consisting of metal foil, paper, cardboard, wood, or a combination thereof. In some cases, the support itself is a laminated structure comprising layers of materials selected from the foregoing list. In some cases, the carrier may also serve as a flavoring carrier. For example, the carrier may be impregnated with a flavour or tobacco extract.

In some cases, the carrier may be substantially or completely impermeable to gases and/or aerosols. This prevents the aerosol or gas from passing through the carrier in use, thereby controlling the flow and ensuring that it is delivered to the user. This may also be used to prevent condensation or other deposition of the gas/aerosol in use on the surface of, for example, a heater provided in the aerosol-generating assembly. Thus, in some cases, consumption efficiency and hygiene can be improved.

In some cases, the carrier in the aerosol-generating article may comprise or consist of a porous layer adjacent to the starch substrate. For example, the porous layer may be a paper layer. In some particular cases, the starch layer is disposed in direct contact with the porous layer; the porous layer adjoins the starch and forms a strong bond. The starch matrix is formed by drying the gel, and without being limited by theory, it is believed that the gel-forming slurry partially impregnates the porous layer (e.g., paper) such that when the gel sets and forms crosslinks, the porous layer is partially incorporated into the gel. This provides a strong bond between the gel and the porous layer (and between the dried gel and the porous layer).

In addition, the surface roughness may contribute to the bond strength between the aerosol-generating material and the carrier. The inventors have found that the paper roughness (for the surface abutting the support) may suitably be in the range of 50-1000 beck seconds (Bekk second), suitably 50-150 beck seconds, suitably 100 beck seconds (measured in an air pressure interval of 50.66-48.00 kPa). (the Bekk smoothness tester (Bekk smoothness tester) is an instrument for determining the smoothness of a paper surface, in which air at a specific pressure leaks between a smooth glass surface and a paper sample, and the time (in seconds) for a fixed volume of air to leak between these surfaces is "Bekk smoothness (Bekk smoothness)")

Conversely, the surface of the carrier facing away from the aerosol-generating material may be arranged to be in contact with the heater, and a smoother surface may provide more efficient heat transfer. Thus, in some cases, the carrier is arranged to have a rougher side adjacent 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 is adjacent to the aerosol-generating material and the properties discussed in the preceding paragraphs are provided by this abutment. The foil backing is substantially impermeable, thereby providing control over the aerosol flow path. A metal foil backing may also be used to conduct heat to the aerosol generating material.

In another case, the foil layer of the paper-backed foil is adjacent to the amorphous solid. The foil is substantially impermeable to prevent water disposed in the amorphous solid from being absorbed into the paper, which would impair the structural integrity of the paper.

In some cases, the carrier is formed of or includes a metal foil, such as aluminum foil. The metal support may allow better conduction of thermal energy to the amorphous solid. Additionally or alternatively, the metal foil may be used as a susceptor in an induction heating system. In a particular embodiment, the carrier comprises a metal foil layer and a support layer, such as paperboard. In these embodiments, the metal foil layer may have a thickness of less than 20 μm, for example from about 1 μm to about 10 μm, suitably about 5 μm.

In some cases, the carrier may be magnetic. This functionality may be used to secure the carrier to the component in use. In some cases, the aerosol-generating substrate may comprise one or more magnets which may be used to secure the substrate to the induction heater in use.

In some cases, the aerosol-generating substrate may comprise a heating device, such as a resistive or inductive heating element, embedded in the aerosol-generating material.

In some cases, the amorphous solid may have a thickness of about 0.015mm to about 1.0 mm. Suitably, the thickness may be in the range of about 0.05mm, 0.1mm or 0.15mm to about 0.5mm or 0.3 mm. The inventors have found that a material with a thickness of 0.2mm is particularly suitable. The inventors have determined that if the aerosol-generating material is too thick, the heating efficiency is compromised. This adversely affects the power consumption in use. Conversely, if the material is too thin, it is difficult to manufacture and handle; very thin materials are more difficult to cast and can be brittle, impairing aerosol formation in use. In some cases, the thickness specified herein is the average thickness of the material. In some cases, the layer thickness may vary by no more than 25%, 20%, 15%, 10%, 5%, or 1%.

The aerosol-generating material may be formed as a sheet. Which may be incorporated into the article in sheet form. In some cases, the aerosol-generating material may be included as a planar sheet, as a bunched or gathered sheet, as a rolled sheet, or as a rolled sheet (i.e. in the form of a tube). In some cases, the sheet material may be used as a wrapper material which at least partially surrounds other elements of the aerosol-generating article, such as another aerosolizable material (e.g. tobacco). In some other cases, the aerosol-generating material may be formed into a sheet and then shredded and incorporated into an article. In some cases, shredded sheet material may be mixed with shredded tobacco and incorporated into an article.

The aerosol-generating material comprising the amorphous solid may have any suitable areal density, for example 30g/m²To 120g/m². In some embodiments, the aerosol-generating material may have a density of about 30 to 70g/m²Or about 40 to 60g/m²The area density of (a). In some embodiments, the amorphous solid may have about 80 to 120g/m²Or about 70 to 110g/m²Or, in particular, about 90 to 110g/m²The area density of (a). Such areal densities may be particularly suitable where the aerosol-generating material is included in the aerosol-generating article/component in sheet form or as a shredded sheet (described further below). For example, having a density of 80 to 120g/m²Has a density comparable to shredded tobacco, so that mixtures of these components are not easily separable.

In some examples, the amorphous solid in sheet form may have a tensile strength of about 200N/m to about 900N/m. In some examples, the amorphous solid may have a tensile strength of 200N/m to 400N/m, or 200N/m to 300N/m, or about 250N/m, for example, where the amorphous solid does not include a filler. Such tensile strength may be particularly suitable for embodiments in which the aerosol-generating material is formed into a sheet and then shredded and incorporated into an aerosol-generating article. In some examples, the amorphous solid may have a tensile strength of 600N/m to 900N/m, or 700N/m to 900N/m, or about 800N/m, for example where the amorphous solid includes a filler. Such tensile strength may be particularly suitable for embodiments in which the aerosol-generating material is included in the aerosol-generating article/component as a rolled sheet, suitably in the form of a tube.

In some cases, the article may additionally include a filter and/or a cooling element. In some cases, the aerosol-generating article may be surrounded by a wrapper (e.g. paper).

A second aspect of the invention provides an aerosol-generating assembly comprising an aerosol-generating article according to the first aspect of the invention and a heater configured to heat, but not burn, an aerosol-generating material.

In some cases, the heater may be a thin film resistance 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, in use, undergoes an exothermic reaction to generate heat. The aerosol-generating assembly may comprise a plurality of heaters. The heater may be powered by a battery.

In some cases, the heater may heat the aerosolizable material to between 120 ℃ and 350 ℃ in use without burning. In some cases, the heater may heat the aerosolizable material to between 140 ℃ and 250 ℃ in use without burning. In some use cases, substantially all of the amorphous solid is less than about 4mm, 3mm, 2mm, or 1mm from the heater. In some cases, the solids are disposed between about 0.010mm and 2.0mm, suitably between about 0.02mm and 1.0mm, suitably between 0.1mm and 0.5mm from the heater. In some cases, these minimum distances may reflect the thickness of the support supporting the amorphous solid. In some cases, the surface of the amorphous solid may directly abut the heater.

In some cases, the heater may be embedded in the aerosol-generating substrate. In some such cases, the heater may be a resistive heater (with exposed contacts for connection to an electrical circuit). In other such cases, the heater may be a susceptor embedded in the aerosol-generating substrate, which is heated by induction.

The aerosol-generating assembly may additionally comprise a cooling element and/or a filter. If present, the cooling element may function or function to cool the gaseous or aerosol components. In some cases, it may be used to cool the gaseous component such that it condenses to form an aerosol. It can also be used to space very hot parts of the 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 component may be a heat-not-burn device. One such heated non-burning is disclosed in WO 2015/062983a2, which is incorporated herein by reference in its entirety. In some cases, the aerosol-generating component may be an electronic tobacco mixing device. An electronic tobacco mixing device is disclosed in WO 2016/135331a1, which is incorporated herein by reference in its entirety.

The aerosol-generating article or component may additionally comprise ventilation holes. These may be provided in the side walls of the article. In some cases, the vent may be provided in the filter and/or cooling element. These holes may allow cool air to be drawn into the article during use, which may mix with the heated volatile components, thereby cooling the aerosol.

The ventilation enhances the generation of visible hot volatiles from the article when the article is heated in use. The heated volatile components are rendered visible by the process of cooling the heated volatile components, so that oversaturation of the heated volatile components occurs. The heated volatile components then undergo droplet formation, also known as nucleation, and finally the aerosol particles of the heated volatile components increase in size by further condensation of the heated volatile components and by condensation of the newly formed droplets by the heated volatile components.

In some cases, the ratio of cool air to the sum of heated volatile components and cool air, referred to as the draft ratio, is at least 15%. A ventilation ratio of 15% enables the heated volatile components to be made visible by the method described above. The visibility of the heated volatile components enables the user to recognize that volatile components have been generated and increases the sensory experience of the smoking experience.

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

The assembly may comprise an integrated aerosol-generating article and heater. For example, the integrated heater may be a combustible or chemical heat source that heats up in use without combusting the aerosol-generating substrate. Alternatively, the assembly may comprise a heater device into which the article is inserted in use, wherein the heater is configured to heat but not burn the aerosol-generating substrate.

Referring to fig. 1 and 2, a partially cut-away cross-sectional view and a perspective view of an example of an aerosol-generating article 101 are shown. The article 101 is suitable 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 apparatus 51 shown in figures 5 to 7 described below. In use, the article 101 may be removably inserted into the device shown in fig. 5 at the insertion point 20 of the device 51.

The article 101 of one example is in the form of a substantially cylindrical rod comprising a body of aerosol-generating material 103 and a filter assembly 105 in the form of a rod. The aerosol-generating material comprises a starch substrate material as described herein. In some embodiments, it may be included in sheet form. In some embodiments, it may be included in the form of shredded sheets. In some embodiments, the aerosol-generating materials described herein may be combined in sheet form and in shredded form.

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

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

In one example, the overall length of the article 101 is between 71mm and 95mm, suitably between 79mm and 87mm, suitably 83 mm.

An axial end of the body of aerosol-generating material 103 can be seen 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 an axial end of the body of aerosol-generating material 103.

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

In one example, the cooling section 107 is an annular tube and is positioned around and defines an air gap within the cooling section. The air gap provides a chamber for the flow of heated volatile components generated from the body of aerosol-generating material 103. The cooling section 107 is hollow to provide a chamber for aerosol accumulation, but is sufficiently rigid to withstand axial compression forces and bending moments that may occur during manufacture and when the article 101 is in use during insertion into the device 51. In one example, the wall thickness of the cooling section 107 is about 0.29 mm.

The cooling section 107 provides physical displacement between the aerosol-generating material 103 and the filter section 109. The physical displacement provided by the cooling section 107 will provide a thermal gradient over the length of the cooling section 107. In one example, the cooling section 107 is configured to provide a temperature difference of at least 40 degrees celsius between the heated volatile components entering a first end of the cooling section 107 and the heated volatile components exiting a second end of the cooling section 107. In one example, the cooling section 107 is configured to provide a temperature difference of at least 60 degrees celsius between the heated volatile components entering a first end of the cooling section 107 and the heated volatile components exiting a second end of the cooling section 107. This temperature difference over the length of the cooling element 107 protects the temperature sensitive filter segment 109 from the high temperature of the aerosol-generating material when the aerosol-generating material 103 is heated by the device 51. If no physical displacement is provided between the filter segment 109 and the body of aerosol-generating material 103 and the heating element of the device 51, the temperature sensitive filter segment 109 may become damaged in use and therefore it will not be able to perform its required function effectively.

In one example, the length of the cooling section 107 is at least 15 mm. In one example, the length of the cooling section 107 is between 20mm and 30mm, more particularly between 23mm and 27mm, more particularly between 25mm and 27mm, suitably 25 mm.

The cooling section 107 is made of paper, which means that it is constructed of a material that does not generate the compounds of interest (e.g., toxic compounds) when used adjacent to the heater of the device 51. In one example, the cooling section 107 is made of a spirally wound paper tube that provides a hollow interior chamber while maintaining mechanical rigidity. The spirally wound paper tube can meet the strict dimensional accuracy requirements of high-speed manufacturing processes in terms of tube length, outer diameter, roundness and straightness.

In another example, the cooling section 107 is a recess formed by hard plug wrap or tipping paper. The stiff plug wrap or tipping paper is manufactured to have sufficient stiffness to withstand the axial compression forces and bending moments that may occur during manufacture and when the article 101 is in use during insertion into the apparatus 51.

The filter segment 109 may be formed of any filter material sufficient to remove one or more volatile compounds from the heated volatile components from the aerosol generating material. In one example, the filter section 109 is made of a monoacetate material such as cellulose acetate. Filter section 109 provides cooling and stimulation reduction of heated volatile components without depleting the amount of heated volatile components to a level that is not satisfactory to the user.

In some embodiments, a capsule (not shown) may be disposed in filter section 109. It may be substantially centrally disposed in filter segment 109, both across the diameter of filter segment 109 and along the length of filter segment 109. In other cases, it may be offset in one or more dimensions. In some cases, if present, the capsules may contain volatile ingredients, such as a fragrance or an aerosol generator.

The density of the cellulose acetate tow material of the filter section 109 controls the pressure drop across the filter section 109, which in turn controls the draw resistance (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 section performs a filtering function in the article 101.

In one example, filter segment 109 is made of a grade 8Y15 filter tow material that provides a filtering effect on the heated volatile material while also reducing the size of condensed aerosol droplets produced by the heated volatile material.

The presence of the filter section 109 provides an insulating effect by providing further cooling of the heated volatile components leaving the cooling section 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 length of the filter segment 109 is between 6mm and 10mm, suitably 8 mm.

The mouth end section 111 is an annular tube, and is located around the mouth end section 111 and defines an air gap inside thereof. The air gap provides a chamber for heated volatile components that flow from filter segment 109. The mouth end section 111 is hollow to provide a chamber for aerosol accumulation while being sufficiently rigid to withstand axial compression forces and bending moments that may be generated during manufacture and during use during insertion of the article into the device 51. In one example, the length of the mouth end section 111 is between 6mm and 10mm, suitably 8 mm.

The mouth end section 111 may be made of a spirally wound paper tube that provides a hollow interior chamber and maintains a critical mechanical stiffness. The spirally wound paper tube can meet strict dimensional accuracy requirements of high-speed manufacturing processes in terms of tube length, outer diameter, roundness and straightness.

The port section 111 provides the function of preventing any liquid condensate that accumulates at the outlet of the filter section 109 from coming into direct contact with the user.

It is to be understood that in one example, the mouth end section 111 and the cooling section 107 may be formed from a single tube, and the filter section 109 is located within the tube separating the mouth end section 111 from the cooling section 107.

Referring to fig. 3 and 4, a partial cross-sectional view and a perspective view of one example of an article 301 are shown. The reference numbers shown in fig. 3 and 4 are the same as those shown in fig. 1 and 2, but in increments of 200.

In the example of the article 301 shown in fig. 3 and 4, a ventilation zone 317 is provided in the article 301 to enable air to flow from the exterior of the article 301 into the interior of the article 301. In one example, the venting region 317 takes the form of one or more vent holes 317 formed through an outer layer of the article 301. Vents may be located in the cooling section 307 to help cool the article 301. In one example, the venting region 317 comprises one or more rows of apertures, and preferably each row of apertures is arranged circumferentially around the article 301 in a cross-section substantially perpendicular to the longitudinal axis of the article 301.

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

In one example, the vent holes 317 are of uniform size. In another example, the vent holes 317 are different sizes. The vents may be made using any suitable technique, for example, one or more of the following: laser technology, mechanical perforation of the cooling section 307 or pre-perforation of the cooling section 307 prior to its formation into the article 301. The vent 317 is positioned to provide effective cooling to the article 301.

In one example, the rows of vents 317 are located at least 11mm from the proximal end 313 of the article, suitably between 31317 mm and 20mm from the proximal end of the article 301. The location of the vent 317 is positioned such that the user does not block the vent 317 when using the article 301.

When the article 301 is fully inserted into the device 51, as can be seen in fig. 6 and 7, providing rows of vents between 31317 mm and 20mm from the proximal end of the article 301 enables the vents 317 to be located outside of the device 51. By providing vents on the exterior of the device, unheated air can enter the article 301 from the exterior of the device 51 through the vents to aid in cooling of the article 301.

The length of the cooling section 307 is such that when the article 301 is fully inserted into the device 51, the cooling section 307 will be partially inserted into the device 51. The length of the cooling section 307 provides a first function of providing a physical gap between the heater means and the heat sensitive filter means 309 of the device 51 and a second function of enabling the vent 317 to be located in the cooling section when the article 301 is fully inserted into the device 51, whilst also being located outside the device 51. As can be seen from fig. 6 and 7, a majority of the cooling element 307 is located within the device 51. However, a portion of the cooling element 307 protrudes out of the device 51. It is this portion of the cooling element 307 that extends out of the device 51 in which the vent 317 is located.

Referring now in more detail to figures 5 to 7, there is shown an example of a device 51 arranged to heat an aerosol generating material to volatilise at least one component of the aerosol generating material, typically to form an aerosol which can be inhaled. The device 51 is a heating device that releases the compound by heating but not burning the aerosol-generating material.

The first end 53 is sometimes referred to herein as the mouth or proximal end 53 of the device 51, and the second end 55 is sometimes referred to herein as the distal end 55 of the device 51. The device 51 has an on/off button 57 to allow the device 51 as a whole to be turned on and off as required by the user.

The device 51 includes a housing 59 for locating and protecting various internal components of the device 51. In the example shown, the housing 59 includes a one-piece sleeve 11 that surrounds the perimeter of the device 51, which is covered by a top panel 17 that generally defines the "top" of the device 51 and a bottom panel 19 that generally defines the "bottom" of the device 51. In another example, the housing includes a front panel, a rear panel, and a pair of opposing 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 secured to the one-piece sleeve 11 to allow easy access to the interior of the device 51, or may be "permanently" secured to the one-piece sleeve 11, for example, to prevent a user from accessing the interior of the device 51. In one example, the

panels

17 and 19 are made of a plastic material, including glass filled nylon, for example, formed by injection molding, and the unitary sleeve 11 is made of aluminum, although other materials and other manufacturing processes may be used.

The top panel 17 of the device 51 has an opening 20 at the mouth end 53 of the device 51 through which, in use, an

article

101, 301 comprising aerosol-generating material may be inserted into the device 51 and removed from the device 51 by a user.

The housing 59 has the heater device 23, the control circuit 25 and the power source 27 positioned or secured therein. In this example, the heater device 23, the control circuit 25, and the power supply 27 are laterally adjacent (i.e., adjacent when viewed from the end), with the control circuit 25 being located generally between the heater device 23 and the power supply 27, although other locations are possible.

The control circuit 25 may comprise a controller, for example a microprocessor device, configured and arranged to control heating of the aerosol-generating material 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, lithium ion batteries, nickel batteries (e.g., nickel cadmium batteries), alkaline batteries, and the like. The battery 27 is electrically coupled to the heater device 23 to supply power to heat the aerosol-generating material in the article (as discussed, to volatilize the aerosol-generating material without causing combustion of the aerosol-generating material) when required and under the control of the control circuitry 25.

An advantage of locating the power supply 27 laterally adjacent the heater means 23 is that a physically larger power supply 25 can be used without causing the device 51 as a whole to be unduly long. As will be appreciated, the typically physically larger power source 25 has a higher capacity (i.e., total electrical energy that can be supplied, typically measured in amp-hours, etc.), so the battery life of the device 51 can be longer.

In one example, the heater device 23 is generally in the form of a hollow cylindrical tube having a hollow internal heating chamber 29 into which an

article

101, 301 comprising aerosol generating material is inserted for heating in use. Different arrangements for the heater means 23 are possible. For example, the heater device 23 may comprise a single heating element, or may be formed of a plurality of heating elements aligned along a longitudinal axis of the heater device 23. The or each heating element may be annular or tubular, or at least part-annular or part-tubular around its circumference. In one 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 ceramic material. Examples of suitable ceramic materials include alumina and aluminum nitride and silicon nitride ceramics, which may be laminated and sintered. Other heating means are also possible, including for example induction heating, infrared heater elements heated by emitting infrared radiation, or resistive heating elements formed by, for example, resistive windings.

In one particular example, the heater device 23 is supported by a stainless steel support tube and includes a polyimide heating element. The heater device 23 is dimensioned such that when the

article

101, 301 is inserted into the device 51, substantially the entire body of

aerosol generating material

103, 303 of the

article

101, 301 is inserted into the heater device 23.

The or each heating element may be arranged such that selected regions of the aerosol-generating material may be independently heated as required, for example sequentially (over time, as described above) or together (simultaneously).

In this example, the heater device 23 is surrounded along at least a portion of its length by a thermal insulator 31. The insulator 31 helps to reduce the amount of heat transferred from the heater device 23 to the exterior of the device 51. This helps to reduce the power requirements on the heater device 23 as it generally reduces heat losses. The insulation 31 also helps to keep the exterior of the device 51 cool during operation of the heater device 23. In one example, the insulator 31 may be a double-walled sleeve that provides a low pressure region between the two walls of the sleeve. That is, the insulation 31 may be, for example, a "vacuum" tube, i.e., a tube that has been at least partially evacuated in order to minimize heat transfer by conduction and/or convection. Other arrangements for the thermal insulator 31 are possible in addition to or instead of the double-walled sleeve, including the use of thermally insulating materials, including, for example, suitable foam-type materials.

The housing 59 may also include various internal support structures 37 for supporting all internal components, as well as the heating device 23.

The device 51 further comprises a collar 33 extending around the opening 20 and projecting therefrom into the interior of the housing 59, and a generally tubular chamber 35 located between the collar 33 and one end of the vacuum sleeve 31. The cavity 35 also includes a cooling structure 35f, which in this example includes a plurality of cooling fins 35f spaced along the outer surface of the cavity 35, and each fin is arranged circumferentially around the outer surface of the cavity 35. When the

product

101, 301 is inserted into the device 51, there is an air gap 36 between the hollow chamber 35 and the

product

101, 301 over at least a portion of the length of the hollow chamber 35. The air gap 36 surrounds the entire circumference of the

article

101, 301 over at least a portion of the cooling segment 307.

Collar 33 includes a plurality of ridges 60 circumferentially disposed about the periphery of opening 20 and extending into opening 20. The ridge 60 occupies space within the opening 20 such that the opening 20 has an open span at the location of the ridge 60 that is less than the open span of the opening 20 at locations without the ridge 60. The ridge 60 is configured to engage with an

article

101, 301 inserted into the device to help secure it within the device 51. The open spaces (not shown in the figures) defined by adjacent pairs of ridges 60 and the

articles

101, 301 form ventilation paths around the exterior of the

articles

101, 301. These ventilation paths allow hot steam that has escaped from the

articles

101, 301 to leave the device 51 and cooling air to flow into the device 51 around the

articles

101, 301 in the air gap 36.

In operation, as shown in fig. 5-7, the

article

101, 301 is removably inserted into the insertion point 20 of the device 51. In one example, with particular reference to figure 6, the body of aerosol-generating

material

103, 303 located towards the

distal end

115, 315 of the

article

101, 301 is fully received within the heater device 23 of the device 51. The

proximal end

113, 313 of the

article

101, 301 extends from the device 51 and serves as a mouthpiece component for the user.

In operation, the heater device 23 will heat the

article

101, 301 to volatilise at least one component of the aerosol generating material from the body of

aerosol generating material

103, 303.

The primary flow path for the heated volatile components from the body of aerosol-generating

material

103, 303 is axially through the

article

101, 301, through the chamber inside the

cooling section

107, 307, through the

filter section

109, 309, through the

mouth end section

111, 313 to the user. In one example, the temperature of the heated volatile components generated from the body of aerosol-generating material is between 60 ℃ and 250 ℃, which may be above an acceptable inhalation temperature for a user. As the heated volatile components travel through the

cooling section

107, 307, they will cool and some volatile components will condense on the inner surface of the

cooling section

107, 307.

In the example of the article 301 shown in fig. 3 and 4, cool air will be able to enter the cooling section 307 via vents 317 formed in the cooling section 307. This cold air will mix with the heated volatile components to provide additional cooling to the heated volatile components.

A third aspect of the invention provides a starch substrate material comprising:

-a flavour or fragrance ingredient of vegetable origin.

Features described herein in relation to "aerosol-generating materials" are illustratively disclosed herein in connection with the third aspect of the invention.

Suitably, the flavour or aroma component of plant origin comprises a tobacco material, such as a tobacco extract.

Suitably, the plant-derived flavour or aroma ingredient may be a powdered ingredient, which is added in an amount of 40% to 300% by weight of the starch.

The present invention also provides a method of manufacturing an aerosol-generating article according to the first aspect, the method comprising:

In some cases, the heating and stirring step may involve heating to about 70-100 ℃, suitably 85 ℃ for up to about 20 minutes. The drying step may involve heating to about 30-70 deg.C, suitably 50 deg.C, for 1-5 hours, suitably about 3 hours.

The method may comprise an additional step comprising shredding the aerosol-generating material prior to incorporating the aerosol-generating material into the aerosol-generating article.

The present invention also provides a slurry comprising:

-a starch;

-a flavour or fragrance ingredient of vegetable origin; and

-water.

In some examples, the slurry has a viscosity of about 10 to about 20Pa · s at 46.5 ℃, for example, a viscosity of about 14 to about 16Pa · s at 46.5 ℃.

The present invention also provides a slurry comprising:

-a starch;

-a powdered tobacco material having an average particle size of less than about 250 μ ι η, wherein the amount of powdered tobacco material is 40% to 300% by weight of the starch;

The present invention also provides a slurry comprising:

-a starch;

Other aspects of the invention include:

(iii) a wrapper for a smoking article or an aerosol-generating article, wherein the wrapper comprises a starch substrate and a plasticiser, wherein the amount of plasticiser is from about 5% to 30% by weight of the starch; and

(iv) a filter for a smoking article or an aerosol-generating article, the filter comprising a starch substrate and a plasticiser, wherein the amount of plasticiser is from about 5% to 15% by weight of the starch.

The present inventors have determined that these starch substrate materials are useful as filters and wrappers in addition to being aerosol generating materials.

Examples of the invention

Example 1

A starch matrix film was prepared as follows:

1000mg of potato starch, 300mg of glycerol and 20mL of water are added to a 50mL beaker. The slurry was stirred using a stir bar and the mixture was heated to 85 ℃ for 10 minutes with vigorous stirring. Thickening (or gelling) of the mixture was observed.

The gel was cast onto a PTFE sheet. (the polarity of the gel is strong so it will adhere strongly to glass or metal). The material was dried at 50 ℃ for 2 hours to produce a film having a thickness of 4 mm.

Example 2

In another example, a starch matrix film was prepared using the method of example 1, wherein 500-2000mg of tobacco powder (particle size 200 μm) was added to the mixture prior to stirring.

Example 3

In another example, a starch matrix film was prepared using the method of example 1, except that 20mL of aqueous tobacco extract (obtained by extracting ground virginia tobacco with deionized water) was used in place of water, and 450mg of glycerol (instead of 300mg) was used.

Testing

The material of each example will be heated without combustion in a simulated puff regime (heating to 250 ℃ with 2 seconds of puff every 30 seconds under a flow of 1.65L/min).

Definition of

An active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropic agents, psychoactive substances. The active substance may be naturally occurring or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, caffeine, vitamins (e.g., B6 or B12 or C), melatonin, or a component, derivative or combination thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco or other plants.

In some embodiments, the active comprises nicotine.

In some embodiments, the active substance comprises caffeine, melatonin, or vitamin B12.

As referred to herein, an active substance may comprise or be derived from one or more plants or constituents, derivatives or extracts thereof. As used herein, the term "plant" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, hulls, husks, and the like. Alternatively, the material may comprise active compounds naturally occurring in plants, which are obtained synthetically. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, chips, strips, sheets, and the like. Examples of plants are tobacco, eucalyptus, anise, cocoa, fennel, lemon grass, mint, spearmint, tea tree, chamomile, flax, ginger, ginkgo leaf, hazelnut, hibiscus, bay, licorice (licorice), matcha, orange peel, papaya, rose, sage, tea (e.g. green or black tea), thyme, clove, cinnamon, coffee, fennel, basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, chili, rosemary, saffron, lavender, lemon peel, mint, juniper, elderberry, vanilla, wintergreen, beefsteak, turmeric, sandalwood, coriander, bergamot, orange blossom, myrtle, blackcurrant, valerian, green pepper, plum, damimean, marjoram, olive, lemon balm, shallot, parsley, verbena, tarragon, tarragweed, mulberry, geranium, mulberry, ginseng, theanine, maca, ashwaganda, damina, guarana, chlorophyll, sinomenia, or any combination thereof. The mint may be selected from the following mint varieties: mentha arvensis, mentha nilla, mentha piperita, mentha limonum, mentha piperita, menthol, mentha piperita, mentha longifolia, cremophorus horrida, pulegium piperita, mentha piperita and peppermint oil.

In some embodiments, the plant is selected from eucalyptus, anise, and cocoa.

In some embodiments, the plant is selected from the group consisting of tea tree and fennel.

As used herein, the terms "flavoring agent" and "aroma" refer to substances that may be used to produce a taste, aroma, or other somatic sensation desired by an adult consumer in a product, as permitted by local regulations. It may include naturally occurring flavoring materials, botanicals, botanical extracts, synthetically obtained materials, or combinations thereof (e.g., tobacco, licorice (licorice), hydrangea, eugenol, japanese magnolia leaves, chamomile, fenugreek, clove, maple, matcha, menthol, japanese mint, anise (anise), cinnamon, turmeric, indian spice, asian spice, herb, wintergreen, cherry, berry, raspberry, cranberry, peach, apple, orange, mango, clematis, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruit, red plum, beefwood, scotch, whisky, gin, tequila, rum, spearmint, mint, lavender, aloe, cardamom, celery, bitter bean peel, nutmeg, sandalwood, bergamot, geranium, kala, sorghum, betel, caraway, pine, honey essence, rose oil, vanilla, lemon oil, orange blossom, cherry blossom, cinnamon, caraway, cognac, jasmine, ylang-ylang, sage, fennel, mustard, allspice, ginger, coriander, coffee, peppermint oil from any mentha species, eucalyptus, anise, cocoa, lemon grass, red leaf, tea tree, ginkgo leaf, hazelnut, hibiscus, bay, orange peel, rose, tea (e.g., green or black tea), thyme, juniper, elderberry, basil, bay leaf, cumin, oregano, capsicum, rosemary, saffron, lemon peel, mint, beefsteak, turmeric, coriander, myrtle, blackcurrant, green pepper, plum, damimen, verbena, olive, lemon balm, caraway, sweet basil, caraway, dragon tree, pine, lemon, caraway, or a, limonene, thymol, camphor), flavor enhancers, bitter receptor site blockers, sensory receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives, such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners. It may be a mimetic, synthetic or natural component or a mixture thereof. It may be in any suitable form, for example, a liquid such as an oil, a solid such as a powder, or a gas.

The flavouring agent may suitably comprise one or more mint flavouring agents, suitably mint oil from any species of the genus mentha. The flavouring agent may suitably comprise, consist essentially of or consist of menthol.

In some embodiments, the flavoring agent comprises menthol, spearmint, and/or peppermint.

In some embodiments, the flavoring agent comprises cucumber, blueberry, citrus fruit, and/or raspberry flavor ingredients.

In some embodiments, the flavoring agent comprises eugenol.

In some embodiments, the flavoring agent comprises a flavor component extracted from tobacco.

In some embodiments, in addition to or in place of the aroma or taste nerves, the flavoring agents may include sensates intended to achieve somatic sensations that are typically chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve), and these may include agents that provide heating, cooling, tingling, numbing effects. A suitable thermogenic agent may be, but is not limited to, vanillyl ether, and a suitable coolant may be, but is not limited to, eucalyptol, WS-3.

As used herein, the term "aerosol-generating agent" refers to an agent that promotes aerosol generation. Aerosol-generating agents may facilitate aerosol generation by promoting initial evaporation and/or condensation of a gas into an inhalable solid and/or liquid aerosol.

As used herein, the term "tobacco material" refers to any material that includes tobacco or derivatives thereof. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. The tobacco material may include one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, reconstituted tobacco, and/or tobacco extracts.

The tobacco used to produce the tobacco material may be any suitable tobacco, such as a single grade or blend, cut tobacco or whole leaf, including virginia and/or burley and/or oriental. It may also be tobacco particulate "fines" or dust, expanded tobacco, stems, expanded stems, and other processed stem material, such as cut rolled stems. The tobacco material may be ground tobacco or reconstituted tobacco material. Reconstituted tobacco material may include tobacco fibers and may be formed by casting, fourdrinier paper-based processes incorporating tobacco extracts, or by extrusion.

All weight percentages (expressed as%) described herein are calculated on a dry weight basis unless explicitly stated otherwise. All weight ratios are also calculated on a dry weight basis. The weights quoted on a dry weight basis refer to the entire extract or slurry or material, except water, and may include ingredients that are liquid themselves at room temperature and pressure, such as glycerin. Conversely, reference to weight percentages on a wet weight basis refers to all ingredients, including water.

For the avoidance of doubt, in this specification the term "comprising" is used to define the invention or a feature of the invention, and also discloses embodiments in which the invention or feature may be defined using the term "consisting essentially of …" or "consisting of …" in place of "comprising". Reference to a material "comprising" certain features means that those features are included, contained or retained within the material.

The above embodiments are to be understood as illustrative examples of the invention. It is to be understood that any feature described in relation to any one embodiment may be used alone, or in combination with other features described, and may also be used in combination with one or more features of any other of the embodiments, or any combination of any other of the embodiments. Furthermore, equivalents and modifications not described above may also be employed without departing from the scope of the invention, which is defined in the accompanying claims.

Claims

1. An aerosol-generating article for an aerosol-generating component, the article comprising an aerosol-generating substrate comprising an aerosol-generating material, wherein the aerosol-generating material is solid and comprises starch and a plasticiser, wherein the plasticiser is in an amount of about 5% to 70% by weight of the starch.

2. An aerosol-generating article according to claim 1, wherein the amount of plasticiser is from about 20% to 50% by weight of the starch.

3. An aerosol-generating article according to any preceding claim, wherein the aerosol-generating material further comprises a tobacco material.

4. An aerosol-generating article according to claim 3, wherein the tobacco material comprises a powdered tobacco material having a particle size of less than about 250 μm.

5. An aerosol-generating article according to claim 5, wherein the tobacco material comprises a tobacco extract.

6. An aerosol-generating article according to any preceding claim, wherein the plasticiser is selected from erythritol, sorbitol, glycerol, glycols such as propylene glycol, monohydric alcohols, high boiling hydrocarbons, lactic acid, diacetin, triacetin, triethylene glycol diacetate, triethyl citrate, ethyl myristate, isopropyl myristate, methyl stearate, dimethyl dodecandioate and dimethyl tetradecanedioate.

7. An aerosol-generating article according to any preceding claim, wherein the starch comprises potato starch.

8. An aerosol-generating article according to any preceding claim, wherein the solid aerosol-generating material is formed as a sheet.

9. An aerosol-generating article according to any preceding claim, wherein the aerosol-generating material has 80-120g/m²Mass per unit area of (c).

10. An aerosol-generating article according to any preceding claim, wherein the aerosol-generating substrate comprises a carrier on which the aerosol-generating material is disposed.

11. An aerosol-generating assembly comprising an aerosol-generating article according to any preceding claim and a heater configured to heat but not burn the aerosol-generating material.

12. A starch substrate material comprising;

-a flavour or fragrance ingredient of vegetable origin.

13. A kit comprising an aerosol-generating article according to any of claims 1 to 10 and a device configured to receive the article in use, the device comprising a heater configured to heat, in use, but not burn, the aerosol-generating material.

14. A method of manufacturing an aerosol-generating article according to any of claims 1 to 10, the method comprising;

(i) mixing the components of the aerosol-generating material in a slurry, heating and stirring the slurry to effect gelation, casting a gel and drying by heating to form the aerosol-generating material; and

(ii) incorporating the aerosol-generating material into an aerosol-generating article.

15. A slurry, comprising:

-a starch;

-a flavour or fragrance ingredient of vegetable origin; and

-water, wherein the weight ratio of the water to the total weight of the other components is between about 10:1 and 20: 1.

16. A slurry, comprising:

-a starch;

-a powdered tobacco material having an average particle size of less than about 250 μ ι η, wherein the amount of powdered tobacco material is about 40% to 300% by weight of the starch;

17. A slurry, comprising:

-a starch;

18. A smoking article or an aerosol-generating article comprising a wrapper, wherein the wrapper comprises a starch substrate and a plasticiser, wherein the plasticiser is present in an amount of about 5% to 30% by weight of the starch.

19. A filter for a smoking article or an aerosol-generating article, the filter comprising a starch substrate and a plasticiser, wherein the amount of the plasticiser is from about 5% to 15% by weight of the starch.

20. A smoking article or an aerosol-generating article comprising a filter according to claim 19.