EP4658097A1

EP4658097A1 - Aerosol generating materials including a botanical material

Info

Publication number: EP4658097A1
Application number: EP24702856.6A
Authority: EP
Inventors: Luis Monsalud; John Paul Mua; Caroline W.H. Clark; Tiffany COMER
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2023-01-31
Filing date: 2024-01-25
Publication date: 2025-12-10
Also published as: JP2026504195A; WO2024161256A1

Abstract

The present disclosure provides aerosol generating materials which include a tobacco material; a non-tobacco botanical material; a binder; and an aerosol former material. The aerosol generating material can be configured for use in aerosol generating components for aerosol delivery devices. Also provided are aerosol generating components and aerosol delivery devices including the aerosol generating material. Such devices utilize electrically generated heat or combustible ignition sources to heat the aerosol generating material, providing an inhalable substance in the form of an aerosol.

Description

AEROSOL GENERATING MATERIALS INCLUDING A BOTANICAL MATERIAL

FIELD OF THE DISCLOSURE

The present disclosure relates to aerosol generating components comprising an aerosol generating material and methods of making the same. The present disclosure further relates to consumables for use within a combustible or non-combustible aerosol provision system, the consumables comprising the aerosol generating component, and to non-combustible and combustible aerosol provision systems.

BACKGROUND

Smoking articles such as cigarettes, cigars and the like burn tobacco during use to create tobacco smoke. Alternatives to these types of articles release an inhalable aerosol or vapor by releasing compounds from a substrate material by heating without burning. These may be referred to as non-combustible smoking articles, aerosol generating assemblies or non-combustible aerosol provision systems. One example of such a product is a heating device which release compounds by heating, but not burning, a solid aerosolizable material. This solid aerosolizable material may, in some cases, contain a tobacco 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-bum devices, tobacco heating devices or tobacco heating products (THP). Various different arrangements for volatilizing at least one component of the solid aerosolizable material are known.

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

Certain such tobacco heating products and electronic tobacco hybrid devices have suffered from inconsistent performance characteristics. For example, some articles have suffered from inconsistent release of inhalable materials, inadequate loading of aerosol forming materials on substrates, or poor sensory characteristics.

BRIEF SUMMARY

The present disclosure relates to aerosol generating components and aerosol delivery devices that utilize electrically generated heat or combustible ignition sources to heat an aerosol generating material in order to provide an inhalable substance in the form of an aerosol for human consumption.

Accordingly, in one aspect, the disclosure provides an aerosol generating material for use in an aerosol delivery device, the aerosol generating material comprising: a tobacco material in particulate form, present in the aerosol generating material in an amount from about 20% to about 90% by weight, based on the total weight of the aerosol generating material; a non-tobacco botanical material selected from the group consisting of eucalyptus, rooibos, star anise, fennel, and combinations thereof; from 0 to about 25% by weight of a binder, based on the total weight of the aerosol generating material; and an aerosol former material.

In some embodiments, the non-tobacco botanical material is in particulate form and is present in an amount in a range from about 5 to about 30% by weight, based on the total weight of the aerosol generating material.

In some embodiments, the non-tobacco botanical material is in the form of an extract and is present in an amount in a range from about 0.5 to about 3% by weight, based on the total weight of the aerosol generating material.

In some embodiments, the binder is selected from the group consisting of alginates, seaweed hydrocolloids, cellulose ethers, starches, gums, dextrans, carrageenan, povidone, pullulan, zein, and combinations thereof.

In some embodiments, the binder is a cellulose ether selected from the group consisting of methylcellulose, hydroxypropylcellulose, hydroxypropylmethylcellulose, hydroxyethyl cellulose, carboxymethylcellulose, and combinations thereof.

In some embodiments, the binder is carboxymethylcellulose.

In some embodiments, the aerosol former material is selected from the group consisting of water, a polyhydric alcohol, a polysorbate, a sorbitan ester, a fatty acid, a fatty acid ester, a wax, a cannabinoid, a terpene, a sugar alcohol, and combinations thereof.

In some embodiments, the aerosol former material comprises a poly hydric alcohol.

In some embodiments, the poly hydric alcohol is present in an amount from about 15 to about 25% by weight, based on the total weight of the aerosol generating material.

In some embodiments, the polyhydric alcohol is selected from the group consisting of glycerol, propylene glycol, 1,3 -propanediol, diethylene glycol, triethylene glycol, triacetin, and combinations thereof.

In some embodiments, the aerosol generating material is in the form of an extruded sheet, comprising: from about 20 to about 70% by weight of the tobacco material in particulate form, based on the total weight of the aerosol generating material; from about 20 to about 30% by weight of the non-tobacco botanical material, present in particulate form, based on the total weight of the aerosol generating material; and the binder in an amount from about 6 to about 25% by weight, based on the total weight of the aerosol generating material.

In some embodiments, the tobacco material is substantially free of nicotine, and is present in an amount by weight from about 20 to about 35%, based on the total weight of the aerosol generating material

In some embodiments, the aerosol generating material is in the form of an extruded sheet, comprising: from about 25 to about 70% by weight of the tobacco material in particulate form, based on the total weight of the aerosol generating material; the non-tobacco botanical material is in the form of an extract, and is present in an amount in a range from about 1.5 to about 3% by weight, based on the total weight of the aerosol generating material; and the binder in an amount from about 6 to about 25% by weight, based on the total weight of the aerosol generating material. In some embodiments, the aerosol generating material is in the form of a cast sheet, comprising: from about 24 to about 36% by weight of the tobacco material in particulate form, based on the total weight of the aerosol generating material; from about 20 to about 30% by weight of the non-tobacco botanical material, present in particulate form, based on the total weight of the aerosol generating material; and the binder in an amount from about 8 to about 12% by weight, based on the total weight of the aerosol generating material.

In some embodiments, the aerosol generating material is in the form of a reconstituted paper sheet comprising from about 70 to about 90% by weight of the tobacco material in particulate form, based on the total weight of the aerosol generating material; and from about 5 to about 15% by weight of the non-tobacco botanical material, present in particulate form, based on the total weight of the aerosol generating material.

In some embodiments, the aerosol generating material is in the form of a reconstituted paper sheet, comprising: from about 70 to about 90% by weight of the tobacco material in particulate form, based on the total weight of the aerosol generating material; and the non-tobacco botanical material is in the form of an extract, and is present in an amount in a range from about 0.5 to about 1.5% by weight, based on the total weight of the aerosol generating material.

In some embodiments, the aerosol generating material is in beaded form, comprising: from about 32 to about 72% by weight of the tobacco material in particulate form, based on the total weight of the aerosol generating material; from about 16 to about 24% by weight of the non-tobacco botanical material, present in particulate form, based on the total weight of the aerosol generating material; and the binder in an amount from about 0.6 to about 1% by weight, based on the total weight of the aerosol generating material.

In some embodiments, the aerosol generating material is in beaded form, comprising: from about 32 to about 72% by weight of the tobacco material in particulate form, based on the total weight of the aerosol generating material; the non-tobacco botanical material is in the form of an extract, and is present in an amount in a range from about 1.5 to about 3% by weight, based on the total weight of the aerosol generating material; the binder in an amount from about 0.6 to about 1% by weight, based on the total weight of the aerosol generating material; and further comprising rice flour in an amount from about 16 to about 24% by weight, based on the total weight of the aerosol generating material.

In some embodiments, the moisture content of the aerosol generating material is from about 12 to about 21% by weight, based on the total weight of the aerosol generating material.

In some embodiments, the tobacco material is substantially free of nicotine.

In some embodiments, the aerosol generating material is substantially free of nicotine.

In another aspect is provided an aerosol generating component comprising the aerosol generating material as disclosed herein.

In some embodiments, the aerosol generating material is blended with an additional tobacco material which is different in character from the particulate tobacco material comprising the aerosol generating material.

In some embodiments, the additional tobacco material comprises reconstituted tobacco, tobacco lamina, fine-cut tobacco, cut-rag tobacco, or a combination thereof. In a further aspect is provided a consumable for use in a non-combustible aerosol provision device, the consumable comprising the aerosol generating component as disclosed herein.

In a still further aspect is provided a non-combustible aerosol provision system comprising a consumable as disclosed herein and a non-combustible aerosol provision device, the non-combustible aerosol provision device comprising an aerosol generating device arranged to generate aerosol from the consumable when the consumable is used with the non-combustible aerosol provision device.

In a yet further aspect is provided a combustible aerosol provision system comprising a consumable as disclosed herein and a combustible aerosol provision device.

The disclosure includes, without limitations, the following embodiments.

Embodiment 1: An aerosol generating material for use in an aerosol delivery device, the aerosol generating material comprising: a tobacco material in particulate form, present in the aerosol generating material in an amount from about 20% to about 90% by weight, based on the total weight of the aerosol generating material; a non-tobacco botanical material selected from the group consisting of eucalyptus, rooibos, star anise, fennel, and combinations thereof; from 0 to about 25% by weight of a binder, based on the total weight of the aerosol generating material; and an aerosol former material.

Embodiment 2: The aerosol generating material of embodiment 1, wherein the non-tobacco botanical material is in particulate form and is present in an amount in a range from about 5 to about 30% by weight, based on the total weight of the aerosol generating material.

Embodiment 3: The aerosol generating material of embodiment 1, wherein the non-tobacco botanical material is in the form of an extract and is present in an amount in a range from about 0.5 to about 3% by weight, based on the total weight of the aerosol generating material.

Embodiment 4: The aerosol generating material of any one of embodiments 1-3, wherein the binder is selected from the group consisting of alginates, seaweed hydrocolloids, cellulose ethers, starches, gums, dextrans, carrageenan, povidone, pullulan, zein, and combinations thereof.

Embodiment 5: The aerosol generating material of any one of embodiments 1-4, wherein the binder is a cellulose ether selected from the group consisting of methylcellulose, hydroxypropylcellulose, hydroxypropylmethylcellulose, hydroxyethyl cellulose, carboxymethylcellulose, and combinations thereof.

Embodiment 6: The aerosol generating material of any one of embodiments 1-5, wherein the binder is carboxymethylcellulose.

Embodiment 7: The aerosol generating material of any one of embodiments 1-6, wherein the aerosol former material is selected from the group consisting of water, a polyhydric alcohol, a polysorbate, a sorbitan ester, a fatty acid, a fatty acid ester, a wax, a cannabinoid, a terpene, a sugar alcohol, and combinations thereof.

Embodiment 8: The aerosol generating material of any one of embodiments 1-7, wherein the aerosol former material comprises a polyhydric alcohol.

Embodiment 9: The aerosol generating material of embodiment 8, wherein the polyhydric alcohol is present in an amount from about 15 to about 25% by weight, based on the total weight of the aerosol generating material. Embodiment 10: The aerosol generating material of embodiment 8, wherein the polyhydric alcohol is selected from the group consisting of glycerol, propylene glycol, 1,3 -propanediol, diethylene glycol, triethylene glycol, triacetin, and combinations thereof.

Embodiment 11: The aerosol generating material of any one of embodiments 1-10 in the form of an extruded sheet, comprising: from about 20 to about 70% by weight of the tobacco material in particulate form, based on the total weight of the aerosol generating material; from about 20 to about 30% by weight of the non-tobacco botanical material, present in particulate form, based on the total weight of the aerosol generating material; and the binder in an amount from about 6 to about 25% by weight, based on the total weight of the aerosol generating material.

Embodiment 12: The aerosol generating material of any one of embodiments 1-11, wherein the tobacco material is substantially free of nicotine, and is present in an amount by weight from about 20 to about 35%, based on the total weight of the aerosol generating material

Embodiment 13: The aerosol generating material of any one of embodiments 1-10 in the form of an extruded sheet, comprising: from about 25 to about 70% by weight of the tobacco material in particulate form, based on the total weight of the aerosol generating material; the non-tobacco botanical material is in the form of an extract, and is present in an amount in a range from about 1.5 to about 3% by weight, based on the total weight of the aerosol generating material; and the binder in an amount from about 6 to about 25% by weight, based on the total weight of the aerosol generating material.

Embodiment 14: The aerosol generating material of any one of embodiments 1-10 in the form of a cast sheet, comprising: from about 24 to about 36% by weight of the tobacco material in particulate form, based on the total weight of the aerosol generating material; from about 20 to about 30% by weight of the non-tobacco botanical material, present in particulate form, based on the total weight of the aerosol generating material; and the binder in an amount from about 8 to about 12% by weight, based on the total weight of the aerosol generating material.

Embodiment 15: The aerosol generating material of any one of embodiments 1-10 in the form of a reconstituted paper sheet, comprising: from about 70 to about 90% by weight of the tobacco material in particulate form, based on the total weight of the aerosol generating material; and from about 5 to about 15% by weight of the non-tobacco botanical material, present in particulate form, based on the total weight of the aerosol generating material.

Embodiment 16: The aerosol generating material of any one of embodiments 1-10 in the form of a reconstituted paper sheet, comprising: from about 70 to about 90% by weight of the tobacco material in particulate form, based on the total weight of the aerosol generating material; and the non-tobacco botanical material is in the form of an extract, and is present in an amount in a range from about 0.5 to about 1.5% by weight, based on the total weight of the aerosol generating material.

Embodiment 17: The aerosol generating material of any one of embodiments 1-10 in beaded form, comprising: from about 32 to about 72% by weight of the tobacco material in particulate form, based on the total weight of the aerosol generating material; from about 16 to about 24% by weight of the non-tobacco botanical material, present in particulate form, based on the total weight of the aerosol generating material; and the binder in an amount from about 0.6 to about 1% by weight, based on the total weight of the aerosol generating material.

Embodiment 18: The aerosol generating material of any one of embodiments 1-10 in beaded form, comprising: from about 32 to about 72% by weight of the tobacco material in particulate form, based on the total weight of the aerosol generating material; the non-tobacco botanical material is in the form of an extract, and is present in an amount in a range from about 1.5 to about 3% by weight, based on the total weight of the aerosol generating material; the binder in an amount from about 0.6 to about 1% by weight, based on the total weight of the aerosol generating material; and further comprising rice flour in an amount from about 16 to about 24% by weight, based on the total weight of the aerosol generating material.

Embodiment 19: The aerosol generating material of any one of embodiments 1-18, wherein the moisture content of the aerosol generating material is from about 12 to about 21% by weight, based on the total weight of the aerosol generating material.

Embodiment 20: The aerosol generating material of any one of embodiments 1-19, wherein the tobacco material is substantially free of nicotine.

Embodiment 21: The aerosol generating material of any one of embodiments 1-20, wherein the aerosol generating material is substantially free of nicotine.

Embodiment 22: An aerosol generating component comprising the aerosol generating material of any one of embodiments 1-21.

Embodiment 23: The aerosol generating component of embodiment 22, wherein the aerosol generating material is blended with an additional tobacco material which is different in character from the particulate tobacco material comprising the aerosol generating material.

Embodiment 24: The aerosol generating component of embodiment 23, wherein the additional tobacco material comprises reconstituted tobacco, tobacco lamina, fine-cut tobacco, cut-rag tobacco, or a combination thereof.

Embodiment 25: A consumable for use in a non-combustible aerosol provision device, the consumable comprising the aerosol generating component of embodiment 22.

Embodiment 26: A non-combustible aerosol provision system comprising the consumable of embodiment 25 and a non-combustible aerosol provision device, the non-combustible aerosol provision device comprising an aerosol generating device arranged to generate aerosol from the consumable when the consumable is used with the non-combustible aerosol provision device.

Embodiment 27: A combustible aerosol provision system comprising the consumable of embodiment 25 and a combustible aerosol provision device.

These and other features, aspects, and advantages of the disclosure will be apparent from a reading of the following detailed description together with the accompanying drawings, which are briefly described below. The invention includes any combination of two, three, four, or more of the above-noted embodiments as well as combinations of any two, three, four, or more features or elements set forth in this disclosure, regardless of whether such features or elements are expressly combined in a specific embodiment description herein. This disclosure is intended to be read holistically such that any separable features or elements of the disclosed invention, in any of its various aspects and embodiments, should be viewed as intended to be combinable unless the context clearly dictates otherwise.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus described aspects of the disclosure in the foregoing general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale. The drawings are exemplary only and should not be construed as limiting the disclosure.

FIG. 1 is a flow chart illustrating a process for preparing reconstituted paper sheets according to a non-limiting embodiment of the disclosure.

FIG. 2 illustrates a perspective schematic view of an aerosol generating component, according to an example embodiment of the disclosure;

FIG. 3 illustrates a schematic cross-section drawing of a substrate portion of an aerosol generating component, according to an example embodiment of the present disclosure;

FIG. 4 is an illustration showing a section view of an example of a consumable according to a nonlimiting embodiment of the disclosure.

FIG. 5 is an illustration showing a perspective view of the article of FIG. 4.

FIG. 6 is an illustration showing a sectional elevation of a consumable according to a non-limiting embodiment of the disclosure.

FIG. 7 is an illustration showing a perspective view of the article of FIG. 6.

FIG. 8 is an illustration showing a perspective view of a non-combustible aerosol provision system according to a non-limiting embodiment of the disclosure.

FIG. 9 is an illustration showing a section view of an example of a non-combustible aerosol provision system according to a non-limiting embodiment of the disclosure.

FIG. 10 is an illustration showing a perspective view of an example of a non-combustible aerosol provision system according to a non-limiting embodiment of the disclosure.

DETAILED DESCRIPTION

The present disclosure will now be described more fully hereinafter with reference to example embodiments thereof. These example embodiments are described so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Indeed, the disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in this specification and the claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Reference to "dry weight percent" or "dry weight basis" refers to weight on the basis of dry ingredients (i.e., all ingredients except water). Reference to "wet weight" refers to the weight of the mixture including water. Unless otherwise indicated, reference to "weight percent" of a material reflects the total wet weight of the material (i.e., including water). As described hereinafter, the present disclosure generally relates to aerosol generating materials, components, and consumables, as well as methods of making the same. Further provided are combustible and non-combustible aerosol provision system comprising the aerosol generating materials, components, and consumables. The aerosol generating components comprise an aerosol generating material. The aerosol generating materials, components, and consumables described herein are capable of generating an aerosol, for example when heated, irradiated, or energized in any other way. The aerosol generating material may, for example, be in the form of a sheet which may or may not contain nicotine.

Aerosol Generating Materials

As described hereinafter, example embodiments of the present disclosure relate to aerosol generating materials for use in an aerosol delivery device. The aerosol generating materials may comprise a variety of materials, alone or in combinations, and may take a variety of forms (e.g., cast or extruded, or paper process sheets, beads, and the like). The aerosol generating materials of the disclosure generally comprise a tobacco material; a non-tobacco botanical material; a binder; and an aerosol former material. The non-tobacco botanical material may be in the form of a particulate material, an extract, or a combination thereof. Each of the components of the aerosol generating material (i.e., tobacco material, non-tobacco botanical material, binder, and aerosol former material) are described further herein below

Tobacco Material

The aerosol generating materials as disclosed herein comprise a tobacco material. The tobacco material can vary in species, form, and type. Generally, the tobacco material is obtained from a harvested plant of the Nicotiana species. Example Nicotiana species include N. tabacum, N. rustica, N. alata, N. arentsii, N. excelsior, N. forgetiana, N. glauca, N. glutinosa, N. gossei, N. kawakamii, N. knightiana, N. langsdorffi, N. otophora, N. setchelli, N. sylvestris, N. tomentosa, N. tomentosiformis, N. undulata, N. x sanderae, N. africana, N. amplexicaulis, N. benavidesii, N. bonariensis, N. debneyi, N. longiflora, N. maritina, N. megalosiphon, N. occidental, N. paniculata, N. plumbaginifolia, N. raimondii, N. rosulata, N. simulans, N. stocktonii, N. suaveolens, N. umbratica, N. velutina, N. wigandioides, N. acaulis, N. acuminata, N. attenuata, N. benthamiana, N. cavicola, N. clevelandii, N. cordifolia, N. corymbosa, N. fragrans, N. goodspeedii, N. linearis, N. miersii, N. nudicaulis, N. obtusifolia, N. occidentalis subsp. Hersperis, N. pauciflora, N. petunioides, N. quadrivalvis, N. repanda, N. rotundifolia, N. solanifolia, and N. spegazzinii. Various representative other types of plants from the Nicotiana species are set forth in Goodspeed, The Genus Nicotiana, (Chonica Botanica) (1954); US Pat. Nos. 4,660,577 to Sensabaugh, Jr. et al.; 5,387,416 to White et al., 7,025,066 to Lawson et al.; 7,798,153 to Lawrence, Jr. and 8,186,360 to Marshall et al.; each of which is incorporated herein by reference. Descriptions of various types of tobaccos, growing practices and harvesting practices are set forth in Tobacco Production, Chemistry and Technology, Davis et al. (Eds.) (1999), which is incorporated herein by reference.

Nicotiana species from which suitable tobacco materials can be obtained can be derived using genetic-modification or crossbreeding techniques (e.g., tobacco plants can be genetically engineered or crossbred to increase or decrease production of components, characteristics or attributes). See, for example, the types of genetic modifications of plants set forth in US Pat. Nos. 5,539,093 to Fitzmaurice et al.; 5,668,295 to Wahab et al.; 5,705,624 to Fitzmaurice et al.; 5,844,119 to Weigl; 6,730,832 to Dominguez et al.; 7,173,170 to Liu et al.; 7,208,659 to Colliver et al. and 7,230,160 to Benning et al.; US Patent Appl. Pub. No. 2006/0236434 to Conkling et al.; and PCT W02008/103935 to Nielsen et al. See, also, the types of tobaccos that are set forth in US Pat. Nos. 4,660,577 to Sensabaugh, Jr. et al.; 5,387,416 to White et al.; and 6,730,832 to Dominguez et al., each of which is incorporated herein by reference.

The Nicotiana species can, in some embodiments, be selected for the content of various compounds that are present therein. For example, plants can be selected on the basis that those plants produce relatively high quantities of one or more of the compounds desired to be isolated therefrom. In certain embodiments, plants of the Nicotiana species (e.g., Galpao commun tobacco) are specifically grown for their abundance of leaf surface compounds. Tobacco plants can be grown in greenhouses, growth chambers, or outdoors in fields, or grown hydroponically.

Various parts or portions of the plant of the Nicotiana species can be included within a substrate as disclosed herein. For example, virtually all of the plant (e.g., the whole plant) can be harvested, and employed as such. Alternatively, various parts or pieces of the plant can be harvested or separated for further use after harvest. For example, the flower, leaves, stem, stalk, roots, seeds, and various combinations thereof, can be isolated for further use or treatment. In some embodiments, the tobacco material comprises tobacco leaf (lamina). The substrate disclosed herein can include processed tobacco parts or pieces, cured and aged tobacco in essentially natural lamina and/or stem form. In certain embodiments, the tobacco material comprises solid tobacco material selected from the group consisting of lamina and stems. The tobacco that is used for the substrate most preferably includes tobacco lamina, or a tobacco lamina and stem mixture (of which at least a portion is smoke treated). Portions of the tobacco may have processed forms, such as processed tobacco stems (e.g., cut-rolled stems, cut-rolled-expanded stems or cut-puffed stems), or volume expanded tobacco (e.g., puffed tobacco, such as dry ice expanded tobacco (DIET)). See, for example, the tobacco expansion processes set forth in US Pat. Nos. 4,340,073 to de la Burde et al.; 5,259,403 to Guy et al.; and 5,908,032 to Poindexter, et al.; and 7,556,047 to Poindexter, et al., all of which are incorporated by reference. In addition, the substrate may incorporate tobacco that has been fermented. See, also, the types of tobacco processing techniques set forth in PCT W02005/063060 to Atchley et al., which is incorporated herein by reference.

The tobacco material is typically used in a form that can be described as particulate, for example, shredded, ground, granulated, pulp, or powder form. In some embodiments, the tobacco material is employed in the form of parts or pieces that have an average particle size between 1.4 millimeters and 25 microns. In some instances, the tobacco particles may be sized to pass through a screen mesh to obtain the particle size range required. If desired, air classification equipment may be used to ensure that small sized tobacco particles of the desired sizes, or range of sizes, may be collected. If desired, differently sized pieces of granulated tobacco may be mixed together. The manner by which the tobacco material is provided in a finely divided or powder type of form may vary. Preferably, plant parts or pieces are milled, comminuted, ground or pulverized into a particulate form using equipment and techniques for grinding, milling, or the like. The plant, or parts thereof, can be subjected to external forces or pressure (e.g., by being pressed or subjected to roll treatment). When carrying out such processing conditions, the plant or portion thereof can have a moisture content that approximates its natural moisture content (e.g., its moisture content immediately upon harvest), a moisture content achieved by adding moisture to the plant or portion thereof, or a moisture content that results from the drying of the plant or portion thereof. For example, powdered, pulverized, ground, pulped or milled pieces of plants or portions thereof can have moisture contents of less than about 25 weight percent, often less than about 20 weight percent, and frequently less than about 15 weight percent. Most preferably, the plant material is relatively dry in form during grinding or milling, using equipment such as hammer mills, cutter heads, air control mills, or the like. For example, tobacco parts or pieces may be ground or milled when the moisture content thereof is less than about 15 weight percent or less than about 5 weight percent.

For the preparation of aerosol generating materials, it is typical for a harvested plant of the Nicotiana species to be subjected to a curing process. The tobacco materials incorporated within the aerosol generating materials as disclosed herein are generally those that have been appropriately cured and/or aged. Descriptions of various types of curing processes for various types of tobaccos are set forth in Tobacco Production, Chemistry and Technology, Davis et al. (Eds.) (1999). Examples of techniques and conditions for curing flue-cured tobacco are set forth in Nestor et al., Beitrage Tabakforsch. Int., 20, 467-475 (2003) and US Pat. No. 6,895,974 to Peele, which are incorporated herein by reference. Representative techniques and conditions for air curing tobacco are set forth in US Pat. No. 7,650,892 to Groves et al.; Roton et al., Beitrage Tabakforsch. Int., 21, 305-320 (2005) and Staaf et al., Beitrage Tabakforsch. Int., 21, 321-330 (2005), which are incorporated herein by reference. Certain types of tobaccos can be subjected to alternative types of curing processes, such as fire curing or sun curing.

In certain embodiments, tobacco materials that can be employed include flue-cured or Virginia (e.g., K326), burley, sun-cured (e.g., Indian Kumool and Oriental tobaccos, including Katerini, Prelip, Komotini, Xanthi and Yambol tobaccos), Maryland, dark, dark-fired, dark air cured (e.g., Madole, Passanda, Cubano, Jatin and Bezuki tobaccos), light air cured (e.g., North Wisconsin and Galpao tobaccos), Indian air cured, Red Russian and Rustica tobaccos, as well as various other rare or specialty tobaccos and various blends of any of the foregoing tobaccos.

The tobacco material may also have a so-called "blended" form. For example, the tobacco material may include a mixture of parts or pieces of flue-cured, burley (e.g., Malawi burley tobacco) and Oriental tobaccos (e.g., as tobacco composed of, or derived from, tobacco lamina, or a mixture of tobacco lamina and tobacco stem). For example, a representative blend may incorporate about 30 to about 70 parts burley tobacco (e.g., lamina, or lamina and stem), and about 30 to about 70 parts flue cured tobacco (e.g., stem, lamina, or lamina and stem) on a dry weight basis. Other example tobacco blends incorporate about 75 parts flue-cured tobacco, about 15 parts burley tobacco, and about 10 parts Oriental tobacco; or about 65 parts flue-cured tobacco, about 25 parts burley tobacco, and about 10 parts Oriental tobacco; or about 65 parts flue-cured tobacco, about 10 parts burley tobacco, and about 25 parts Oriental tobacco; on a dry weight basis. Other example tobacco blends incorporate about 20 to about 30 parts Oriental tobacco and about 70 to about 80 parts flue-cured tobacco on a dry weight basis.

Tobacco materials used in the present disclosure can be subjected to, for example, fermentation, bleaching, and the like. If desired, the tobacco materials can be, for example, irradiated, pasteurized, or otherwise subjected to controlled heat treatment. Such treatment processes are detailed, for example, in US Pat. No. 8,061,362 to Mua et al., which is incorporated herein by reference. In certain embodiments, tobacco materials can be treated with water and an additive capable of inhibiting reaction of asparagine to form acrylamide upon heating of the tobacco material (e.g., an additive selected from the group consisting of lysine, glycine, histidine, alanine, methionine, cysteine, glutamic acid, aspartic acid, proline, phenylalanine, valine, arginine, compositions incorporating di- and trivalent cations, asparaginase, certain non-reducing saccharides, certain reducing agents, phenolic compounds, certain compounds having at least one free thiol group or functionality, oxidizing agents, oxidation catalysts, natural plant extracts (e.g., rosemary extract), and combinations thereof. See, for example, the types of treatment processes described in US Pat. Pub. Nos. 8,434,496, 8,944,072, and 8,991,403 to Chen et al., which are all incorporated herein by reference. In certain embodiments, this type of treatment is useful where the original tobacco material is subjected to heat in the processes previously described.

In some embodiments, the type of tobacco material is selected such that it is initially visually lighter in color than other tobacco materials to some degree (e.g., whitened or bleached). Tobacco pulp can be whitened in certain embodiments according to any means known in the art. For example, bleached tobacco material produced by various whitening methods using various bleaching or oxidizing agents and oxidation catalysts can be used. Example oxidizing agents include peroxides (e.g., hydrogen peroxide), chlorite salts, chlorate salts, perchlorate salts, hypochlorite salts, ozone, ammonia, potassium permanganate, and combinations thereof. Example oxidation catalysts are titanium dioxide, manganese dioxide, and combinations thereof. Processes for treating tobacco with bleaching agents are discussed, for example, in US Patent Nos. 787,611 to Daniels, Jr.; 1,086,306 to Oelenheinz; 1,437,095 to Delling; 1,757,477 to Rosenhoch; 2,122,421 to Hawkinson; 2,148,147 to Baier; 2,170,107 to Baier; 2,274,649 to Baier; 2,770,239 to Prats et al.; 3,612,065 to Rosen; 3,851,653 to Rosen; 3,889,689 to Rosen; 3,943,940 to Minami; 3,943,945 to Rosen; 4,143,666 to Rainer; 4,194,514 to Campbell; 4,366,823, 4,366,824, and 4,388,933 to Rainer et al.; 4,641,667 to Schmekel et al.; 5,713,376 to Berger; 9,339,058 to Byrd Jr. et al.; 9,420,825 to Beeson et al.; and 9,950,858 to Byrd Jr. et al.; as well as in US Pat. App. Pub. Nos. 2012/0067361 to Bjorkholm et al.; 2016/0073686 to Crooks; 2017/0020183 to Bjorkholm; and 2017/0112183 to Bjorkholm, and in PCT Publ. Appl. Nos. WO1996/031255 to Giolvas and W02018/083114 to Bjorkholm, all of which are incorporated herein by reference.

In some embodiments, the whitened tobacco material can have an ISO brightness of at least about 50%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, or at least about 80%. In some embodiments, the whitened tobacco material can have an ISO brightness in the range of about 50% to about 90%, about 55% to about 75%, or about 60% to about 70%. ISO brightness can be measured according to ISO 3688: 1999 or ISO 2470-1:2016.

In some embodiments, the whitened tobacco material can be characterized as lightened in color (e.g., "whitened") in comparison to an untreated tobacco material. White colors are often defined with reference to the International Commission on Illumination's (CIE's) chromaticity diagram. The whitened tobacco material can, in certain embodiments, be characterized as closer on the chromaticity diagram to pure white than an untreated tobacco material.

The tobacco material may be processed to remove at least a portion of the nicotine present. Suitable methods of extracting nicotine from tobacco material are known in the art. In some embodiments, the tobacco material is substantially free of nicotine. By "substantially free" is meant that only trace amounts are present in the tobacco material. For example, in certain embodiments, the tobacco material can be characterized as having less than 0.001% by weight of nicotine, or less than 0.0001%, or even 0% by weight of nicotine, calculated as the free base, and based on the total weight of the tobacco material.

The quantity of tobacco material present in the aerosol generating material may vary based on the physical form of the aerosol generating material (e.g., extruded sheet, cast sheet, beads, paper recon sheets, and the like) and the specific application. Generally, the quantity of tobacco material present is at least about 20% by weight of the aerosol generating material, and up to about 90% by weight, based on the total weight of the aerosol generating material. For example, a tobacco material may be present in a quantity from about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, or about 55%, to about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, or about 90% by weight of the aerosol generating material, based on the total weight of the aerosol generating material.

In some embodiments, the tobacco material is present in the aerosol generating material in an amount from about 20 to about 90% by weight, based on the total weight of the aerosol generating material. In some embodiments, the tobacco material is present in the aerosol generating material in an amount from about 25 to about 70% by weight, based on the total weight of the aerosol generating material. In some embodiments, the tobacco material is present in the aerosol generating material in an amount from about 70 to about 90% by weight, based on the total weight of the aerosol generating material. In some embodiments, the tobacco material is present in the aerosol generating material in an amount from about 32 to about 72% by weight, based on the total weight of the aerosol generating material. In some embodiments, the tobacco material is present in the aerosol generating material in an amount from about 24 or 25% to about 36% by weight, based on the total weight of the aerosol generating material. In some embodiments, the tobacco material is present in the aerosol generating material in an amount from about 46 to about 70% by weight, based on the total weight of the aerosol generating material. In some embodiments, the tobacco material is present in the aerosol generating material in an amount from about 20 to about 35% by weight, based on the total weight of the aerosol generating material.

In particular embodiments, the tobacco material is substantially free of nicotine. In particular embodiments, the tobacco material is present in the aerosol generating material in an amount less than 0.01% by weight, based on the total weight of the aerosol generating material. Tobacco-derived materials

In some embodiments, the aerosol generating material further comprises a tobacco extract, such as an aqueous tobacco extract, added either as a component of the aerosol former material, or added separately (e.g., during aerosol generating material preparation, or impregnated in the aerosol generating material after formation). "Tobacco extract" as used herein refers to the isolated components of a tobacco material that are extracted from solid tobacco pulp by a solvent (e.g., water) that is brought into contact with the tobacco material in an extraction process. Various extraction techniques of tobacco materials can be used to provide a tobacco extract and tobacco solid material. See, for example, the extraction processes described in US Pat. Appl. Pub. No. 2011/0247640 to Beeson et al., which is incorporated herein by reference. Other example techniques for extracting components of tobacco are described in US Pat. Nos. 4,144,895 to Fiore; 4,150,677 to Osborne, Jr. et al.; 4,267,847 to Reid; 4,289,147 to Wildman et al.; 4,351,346 to Brummer et al.; 4,359,059 to Brummer et al.; 4,506,682 to Muller; 4,589,428 to Keritsis; 4,605,016 to Soga et al.; 4,716,911 to Poulose et al.; 4,727,889 to Niven, Jr. et al.; 4,887,618 to Bemasek et al.; 4,941,484 to Clapp et al.; 4,967,771 to Fagg et al.; 4,986,286 to Roberts et al.; 5,005,593 to Fagg et al.; 5,018,540 to Grubbs et al.; 5,060,669 to White et al.; 5,065,775 to Fagg; 5,074,319 to White et al.; 5,099,862 to White et al.; 5,121,757 to White et al.; 5,131,414 to Fagg; 5,131,415 to Munoz et al.; 5,148,819 to Fagg; 5,197,494 to Kramer; 5,230,354 to Smith et al.; 5,234,008 to Fagg; 5,243,999 to Smith; 5,301,694 to Raymond et al.; 5,318,050 to Gonzalez-Parra et al.; 5,343,879 to Teague; 5,360,022 to Newton; 5,435,325 to Clapp et al.; 5,445,169 to Brinkley et al.; 6,131,584 to Lauterbach; 6,298,859 to Kierulff et al.; 6,772,767 to Mua et al.; and 7,337,782 to Thompson, all of which are incorporated by reference herein.

In some embodiments, the aerosol generating material comprises a tobacco extract, in aqueous or dry powder form, in an amount of from about 1 to about 5% by weight, based on the total weight of the aerosol generating material.

N on-Tobacco Botanical

The aerosol generating materials as disclosed herein comprise a non-tobacco botanical material. As used herein, the term "botanical material" or "botanical" refers to any plant material or fungal-derived material, including plant material in its natural form and plant material derived from natural plant materials, such as extracts or isolates from plant materials or treated plant materials (e.g., plant materials subjected to heat treatment, fermentation, chemical, or other treatment processes capable of altering the chemical or biological nature of the material). For the purposes of the present disclosure, a "botanical material" includes but is not limited to "herbal materials," which refer to seed-producing plants that do not develop persistent woody tissue and are often valued for their medicinal or sensory characteristics (e.g., teas or tisanes). Reference to botanical material as "non-tobacco" is intended to exclude tobacco materials (i.e., does not include any Nicotiana species). The botanical materials used in the present disclosure may comprise, without limitation, any of the compounds and sources set forth herein, including mixtures thereof. Certain botanical materials of this type are sometimes referred to as dietary supplements, nutraceuticals, "phytochemicals" or "functional foods." " Non-limiting examples of botanical materials include without limitation acai berry (Euterpe oleracea martius), acerola (Malpighia glabra), alfalfa, allspice, Angelica root, anise (e.g., star anise), annatto seed, apple (Malus domestica), apricot oil, bacopa monniera, basil (Ocimum basilicum), bee balm, beet root, bergamot, blackberry (Morus nigra , black cohosh, black pepper, black tea, blueberries, boldo (Peumus boldus), borage, bugleweed, cacao, calamus root, camu (Myrcaria dubia), cannabis/hemp, caraway seed, catnip, catuaba, cayenne, cayenne pepper, chaga mushroom, chamomile, cherry, chervil, chocolate, cinnamon (Cinnamomum cassia), citron grass (Cymbopogon citratus), clary sage, cloves, coconut (Cocos nucifera), coffee, comfrey leaf and root, coriander seed, cranberry, dandelion, Echinacea, elderberry, elderflower, endro (Anethum graveolens), evening primrose, eucalyptus, fennel, feverfew, garlic, ginger (Zingiber officinale), gingko biloba, ginseng, goji berries, goldenseal, grape seed, grapefruit, grapefruit rose (Citrus paradisi), graviola (Annona muricata), green tea, gutu kola, hawthorn, hibiscus flower (Hibiscus sabdariffa), honeybush, jiaogulan, kava, jambu (Spilanthes oleraceae), jasmine (Jasminum officinale), juniper berry (Juniperus communis), lavender, lemon (Citrus limon), licorice, lilac, Lion’s mane, maca (Lepidium meyenii), maijoram, milk thistle, mints (menthe), oolong tea, orange (Citrus sinensis), oregano, papaya, pennyroyal, peppermint (Mentha piperita), potato peel, quince, red clover, rooibos (red or green), rosehip (Rosa canina), rosemary, sage, Saint John's Wort, salvia (Salvia officinalis), savory, saw palmetto, silybum marianum, slippery elm bark, sorghum bran hi-tannin, sorghum grain hi-tannin, spearmint (Mentha spicata), spirulina, sumac bran, thyme, turmeric, uva ursi, valerian, vanilla, wild yam root, Wintergreen, withania somnifera, yacon root, yellow dock, yerba mate, and yerba santa.

In some embodiments, the non-tobacco botanical material is selected from the group consisting of eucalyptus, rooibos, star anise, fennel, ginger, lavender, jasmine, clove and combinations thereof. In some embodiments, the non-tobacco botanical material is selected from the group consisting of eucalyptus, rooibos, star anise, fennel, and combinations thereof. In some embodiments, the non-tobacco botanical material comprises eucalyptus, rooibos, star anise, fennel, or combinations thereof. In some embodiments, the non-tobacco botanical material is eucalyptus, rooibos, star anise, fennel, or a combination thereof.

In some embodiments, the non-tobacco botanical material is present in particulate form. The non- tobacco botanical material in particulate form may have a range of particle sizes. For example, in some embodiments, the non-tobacco botanical material has a particle size of from about 0.05 mm to about 1 mm. In some instances, the non-tobacco botanical material particles may be sized to pass through a screen mesh to obtain the particle size range required. In some embodiments, the non-tobacco botanical material in particulate form comprises eucalyptus, rooibos, star anise, fennel, or combinations thereof. In some embodiments, the non-tobacco botanical material in particulate form is selected from the group consisting of eucalyptus, rooibos, star anise, fennel, ginger, lavender, jasmine, clove and combinations thereof. In some embodiments, the non-tobacco botanical material in particulate form is selected from the group consisting of eucalyptus, rooibos, star anise, fennel, and combinations thereof.

In some embodiments, the non-tobacco botanical material is present in the form of an extract. "Botanical extract" as used herein refers to the isolated components of a botanical material that are extracted from a solid botanical material by a solvent (e.g., water, alcohol, or the like) that is brought into contact with the solid botanical material in an extraction process. Various extraction techniques of solid botanical materials can be used to provide a botanical material extract. In some embodiments, the botanical extract is an extract of Angelica root, caraway seed, cinnamon, clove, coriander seeds, elderberry, elderflower, ginger, jasmine, lavender, lilac, peppermint (Mentha piperita), quince, or combinations thereof. In some embodiments, the non-tobacco botanical material in extract form comprises eucalyptus, rooibos, star anise, fennel, or combinations thereof. In some embodiments, the non-tobacco botanical material in extract form is selected from the group consisting of eucalyptus, rooibos, star anise, fennel, and combinations thereof.

In some embodiments, aerosol generating materials prepared from particulate (e.g., milled) botanical materials provide superior aromatic character relative to aerosol generating materials prepared from extracts. In particular, in certain embodiments, low amounts of eucalyptus-specific compounds present in eucalyptus extract resulted in a low perceived aromatic character of aerosol generating materials comprising the extract relative to materials prepared from milled eucalyptus. Accordingly, in certain embodiments, it may be beneficial to utilize particulate (e.g., milled) botanical materials in the aerosol generating materials.

The quantity of non-tobacco botanical material present may vary based on the physical form of the aerosol generating material (e.g., extruded sheet, cast sheet, beads, paper recon sheets, and the like) and the specific application. Generally, the quantity of non-tobacco botanical material present is less than about 50% by weight of the aerosol generating material, based on the total weight of the aerosol generating material. For example, a non-tobacco botanical material may be present in a quantity from about 0.1%, about 0.5%, about 1%, about 5%, about 10%, about 15%, about 20%, or about 25%, to about 30%, about 35%, about 40%, about 45%, or about 50% by weight of the aerosol generating material, based on the total weight of the aerosol generating material.

In some embodiments, the non-tobacco botanical material is in particulate form, and is present in the aerosol generating material in a quantity from about 15 to about 40% by weight, or from about 20 to about 35% by weight, based on the total weight of the aerosol generating material. In some embodiments, the non-tobacco botanical material in particulate form is present in the aerosol generating material in a quantity from about 16 to about 24% by weight, based on the total weight of the aerosol generating material. In some embodiments, the non-tobacco botanical material in particulate form is present in the aerosol generating material in a quantity from about 20 to about 30% by weight, based on the total weight of the aerosol generating material. In some embodiments, the non-tobacco botanical material in particulate form is present in the aerosol generating material in a quantity from about 5 to about 15% by weight, based on the total weight of the aerosol generating material.

In some embodiments, the non-tobacco botanical material is present as an extract, either in place of or in addition to any non-tobacco botanical material in particulate form. In some embodiments, the non- tobacco botanical material in extract form is present in the aerosol generating material in an amount from about 0.5 to about 5%, or from about 0.5 to about 3%, such as from about 0.5 to about 1.5%, or from about 1.5 to about 3% by weight, based on the total weight of the aerosol generating material.

Binder The aerosol generating materials as disclosed herein comprise a binder. A binder (or combination of binders) is employed in amounts sufficient to provide the desired physical attributes and physical integrity to the aerosol generating material. The amount of binder utilized can vary based on the physical form of 'the " aerosol generating material (e.g., extruded sheet, cast sheet, beads, reconstituted paper sheets, and the like) and the specific application. Typically, the amount of binder present is up to about 25% by weight, and certain embodiments are characterized by a binder content of at least about 0.5% by weight, based on the total weight of the aerosol generating material. In some embodiments, the binder is present in an amount by weight in a range from about 0.6 to about 25% based on the total weight of the aerosol generating material, such as from about 0.6%, about 1%, about 1.5%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8, about 9%, about 10%, about 11%, or about 12%, to about 15%, about 20%, or about 25% by weight, based on the total weight of the aerosol generating material In some embodiments, the binder is present in an amount by weight from about 0.6 to about 1% based on the total weight of the aerosol generating material. In some embodiments, the binder is present in an amount by weight from about 6 to about 25%, such as from about 8 to about 12%, based on the total weight of the substrate.

Typical binders can be organic or inorganic, or a combination thereof. Representative binders include povidone, sodium alginate, pectin, gums, carrageenan, pullulan, zein, cellulose derivatives, and the like, and combinations thereof. In some implementations, combinations or blends of two or more binder materials may be employed. Other examples of binder materials are described, for example, in U.S. Pat. No. 5,101,839 to Jakob et al.; and U.S. Pat. No. 4,924,887 to Raker et al., each of which is incorporated herein by reference in its entirety.

In some embodiments, the binder is selected from the group consisting of alginates, carrageenan and other seaweed hydrocolloids, exudate gum hydrocolloids, cellulose ethers, starches, gums, dextrans, povidone, pullulan, zein, or combinations thereof.

In some embodiments, the binder is a cellulose ether (including carboxyalkyl ethers), meaning a cellulose polymer with the hydrogen of one or more hydroxyl groups in the cellulose structure replaced with an alkyl, hydroxyalkyl, or aryl group. Non-limiting examples of such cellulose derivatives include methylcellulose, hydroxypropylcellulose ("HPC"), hydroxypropylmethylcellulose ("HPMC"), hydroxyethyl cellulose, and carboxymethylcellulose ("CMC"). Suitable cellulose ethers include hydroxypropylcellulose, such as Klucel H from Aquaion Co.; hydroxypropylmethylcellulose, such as Methocel K4MS from DuPont; hydroxyethylcellulose, such as Natrosol 250 MRCS from Aquaion Co.; methylcellulose, such as Methocel A4M, K4M, and E15 from DuPont.; and sodium carboxymethylcellulose, such as CMC 7HF, CMC 7LF, and CMC 7H4F from Aquaion Co. In some embodiments, the binder is one or more cellulose ethers (e.g., a single cellulose ether or a combination of several cellulose ethers, such as two or three, for example). In some embodiments, the binder is a cellulose ether selected from the group consisting of methylcellulose, hydroxypropylcellulose, hydroxypropylmethylcellulose, hydroxyethyl cellulose, carboxymethylcellulose, and combinations thereof. It is to be understood that in embodiments where the substrate comprises more than one cellulose ether, the stated weight basis of the binder reflects the total weight of the combination of cellulose ethers, based on the total wet weight of the substrate. In some embodiments, the binder is carboxymethylcellulose.

Fillers

In some embodiments, the aerosol generating materials as disclosed herein comprise one or more fillers. The one or more fillers may comprise materials such as calcium carbonate starches, wood fibers, pulps, cellulose and cellulose derivatives, crushed seashells, inert materials, and the like.

When present, the amount of filler can vary. In some embodiments, the aerosol generating material comprises up to about 30% by weight of one or more fillers, based on the total weight of the substrate. For example, in some embodiments, the aerosol generating material comprises from about 0 to about 25% of one or more fillers, such as from about 0.1%, about 1%, or about 5%, to about 10%, about 15%, about 20%, or about 25% filler by weight, based on the total weight of the aerosol generating material. In some embodiments, the aerosol generating material comprises from about 3 to about 5%, from about 5 to about 15%, or from about 15 to about 25%, such as from about 16 to about 24% filler by weight, based on the total weight of the aerosol generating material.

In some embodiments, the one or more fillers comprise a starch, including native and modified starches. "Starch" as used herein may refer to pure starch from any source, modified starch, or starch derivatives. Starch is present, typically in granular form, in almost all green plants and in various types of plant tissues and organs (e.g., seeds, leaves, rhizomes, roots, tubers, shoots, fruits, grains, and stems). Starch can vary in composition, as well as in granular shape and size. Often, starch from different sources has different chemical and physical characteristics. A specific starch can be selected for inclusion in the beads based on the ability of the starch material to impart a specific organoleptic property to the beads. Starches derived from various sources can be used. For example, major sources of starch include cereal grains (e.g., rice, wheat, and maize) and root vegetables (e.g., potatoes and cassava). Other examples of sources of starch include acorns, arrowroot, arracacha, bananas, barley, beans (e.g., favas, lentils, mung beans, peas, chickpeas), breadfruit, buckwheat, canna, chestnuts, colacasia, katakuri, kudzu, malanga, millet, oats, oca, Polynesian arrowroot, sago, sorghum, sweet potato, quinoa, rye, tapioca, taro, tobacco, water chestnuts, and yams. Suitable starches include, but are not limited to, com starch, rice starch, and modified food starches. Certain starches are modified starches. A modified starch has undergone one or more structural modifications, often designed to alter its high heat properties. Some starches have been developed by genetic modifications and are considered to be "modified" starches. Other starches are obtained and subsequently modified. For example, modified starches can be starches that have been subjected to chemical reactions, such as esterification, etherification, oxidation, depolymerization (thinning) by acid catalysis or oxidation in the presence of base, bleaching, transglycosylation and depolymerization (e.g., dextrinization in the presence of a catalyst), cross-linking, enzyme treatment, acetylation, hydroxypropylation, and/or partial hydrolysis. Other starches are modified by heat treatments, such as pregelatinization, dextrinization, and/or cold-water swelling processes. Certain modified starches include monostarch phosphate, distarch glycerol, distarch phosphate esterified with sodium trimetaphosphate, phosphate distarch phosphate, acetylated distarch phosphate, starch acetate esterified with acetic anhydride, starch acetate esterified with vinyl acetate, acetylated distarch adipate, acetylated distarch glycerol, hydroxypropyl starch, hydroxypropyl distarch glycerol, and starch sodium octenyl succinate.

In some embodiments, the one or more fillers comprises com starch, rice starch or rice flour, modified food starch, or a combination thereof. In some embodiments, the one or more fdlers is rice starch or rice flour. In some embodiments, the aerosol generating material comprises from about 16 to about 24% rice flour, based on the total weight of the substrate.

In some embodiments, the one or more fillers comprises a cellulose material, such as a cellulose pulp. In some embodiments, the aerosol generating material comprises from about 1 to about 10% cellulose pulp, such as from about 1, about 2, about 3, about 4, or about 5%, to about 6, about 7, about 8, about 9, or about 10% cellulose pulp, based on the total weight of the substrate. The source of the pulp may vary. In some embodiments, the cellulose pulp is the material remaining after extraction of water-soluble substances from a plant material, such as tobacco or a non-tobacco botanical material.

In some embodiments, the one or more fillers comprises wood fibers. For example, in some embodiments, the one or more fillers comprises, on a dry weight basis, from about 0 to about 5% of wood fibers or wood-derived fibers, for example, about 0%, about 1%, about 2%, about 3%, about 4%, or about 5% wood fibers or wood-derived fibers. In other embodiments, the substrate is substantially or completely free of wood fibers or wood pulp. By "substantially free" of wood fibers or pulp is meant that no wood fibers or pulp have been intentionally added, beyond trace amounts that may be naturally present in e.g., a botanical or other plant material. For example, certain embodiments may be characterized as having less than 0.1% by dry weight, or less than 0.01% by dry weight, or less than 0.001% by dry weight, or 0% by dry weight of wood fibers or pulp, based on the total dry weight of the substrate.

In some embodiments, the one or more fillers comprise an inorganic substance or inert substance, such as, but not limited to, chitosan, carbons (graphite, diamond, fullerenes, graphene), quartz, granite, diatomaceous earth, calcium carbonate, calcium phosphate, clays, crustacean and other marine shells, or combinations thereof.

Water

The moisture (e.g., water) content of the aerosol generating material may vary. For example, in some embodiments, the aerosol generating material comprises from about 0% to about 30% water. In some embodiments, the aerosol generating material is dried to remove at least a portion of the water present during preparation. In some embodiments, after drying, the aerosol generating material comprises from about from about 3 to about 21% water, based on the total weight of the substrate. In some embodiments, after drying, the aerosol generating material comprises from about 8 to about 10, or from about 12 to about 18% water, based on the total weight of the aerosol generating material. In some embodiments, after drying, the aerosol generating material comprises from about 15 to about 21% water, based on the total weight of the aerosol generating material. 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).

Aerosol former material The aerosol generating materials as disclosed herein comprise an aerosol former material, which may also be referred to as a humectant. Suitable aerosol former materials include, but are not limited to, water, polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, terpenes, sugar alcohols, tobacco extract, and combinations thereof. In some embodiments, the aerosol former material may include water, polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, terpenes, sugar alcohols, tobacco extract, or a combination of any thereof. Each of polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, terpenes, and sugar alcohols are further described herein below.

The amount of aerosol former material that is present in the aerosol generating material may vary. For example, in certain embodiments, sufficient amounts of aerosol former material are employed in order to provide for the generation of a visible mainstream aerosol that in many regards resembles the appearance of tobacco smoke. The amount of aerosol former materials present may be dependent upon factors such as the number of puffs desired per aerosol generating component. Generally, the aerosol generating material includes a relatively large percentage by weight of the aerosol former material (e.g., one or more polyhydric alcohols, such as glycerol), allowing for aerosol production from the aerosol generating material when heated.

In some embodiments, the aerosol generating material comprises the aerosol former material in an amount of at least about 1% by weight, at least about 10% by weight, of at least about 15% by weight, at least about 20% by weight, at least about 25% by weight, at least about 30% by weight, at least about 35% by weight, at least about 40% by weight, at least about 45% by weight, at least about 50% by weight, at least about 55% by weight, or at least about 60% by weight, based on a total weight of the substrate. Example ranges of total aerosol former materials include about 15% to about 60% by weight, such as about 15% to about 55%, or about 15% to about 25%, based on the total weight of the aerosol generating material.

In some embodiments, the aerosol generating material comprises about 1 wt%, 5 wt%, 10 wt%, 12 wt% or 13 wt% to about 18 wt%, 20 wt%, 25 wt%, 30 wt%, 35 wt%, 45 wt%, 55 wt%, 65 wt%, 75 wt% or 80 wt% of aerosol former material (all calculated on a dry weight basis). In some embodiments, the aerosol generating material comprises about 1-80 wt%, 1-50 wt%, 5-35 wt%, 10-25 wt%, 15-25 wt%, 12-20 wt% or 13-18 wt% of aerosol former material (all calculated on a dry weight basis).

In some embodiments, the aerosol former material comprises one or more polyhydric alcohols. Examples of poly hydric alcohols include glycerol, propylene glycol, and other glycols such as 1,3- propanediol, diethylene glycol, and triethylene glycol. In some embodiments, the polyhydric alcohol is selected from the group consisting of glycerol, propylene glycol, 1,3 -propanediol, diethylene glycol, triethylene glycol, triacetin, and combinations thereof.

In some embodiments, the polyhydric alcohol is a mixture of glycerol and propylene glycol. The glycerol and propylene glycol may be present in various ratios, with either component predominating depending on the intended application. In some embodiments, the glycerol and propylene glycol are present in a ratio by weight of from about 3: 1 to about 1:3. In some embodiments, the glycerol and propylene glycol are present in a ratio by weight of about 3:1, about 2:1, about 1:1, about 1:2, or about 1:3. In some embodiments, the glycerol and propylene glycol are present in a ratio of about 1 : 1 by weight.

In some embodiments, the aerosol former material comprises one or more polysorbates. Examples of polysorbates include Polysorbate 60 (polyoxyethylene (20) sorbitan monostearate; Tween® 60) and Polysorbate 80 (polyoxyethylene (20) sorbitan monooleate; Tween® 80). The type of polysorbate used or the combination of polysorbates used depends on the intended effect desired, as the different polysorbates offer different attributes due to molecular sizes. For example, the polysorbate molecules increase in size from polysorbate 20 to polysorbate 80. Using smaller size polysorbate molecules creates less vapor quantity but permits deeper lung penetration. This may be desirable when the user is in public where he would not want to create a large plume of "smoke" (i.e., vapors). Conversely, if a dense vapor is desired, which can convey the aromatic constituents of tobacco, larger polysorbate molecules can be employed. An additional benefit of using the polysorbate family of compounds is that the polysorbates lower the heat of vaporization of mixtures in which they are present.

In some embodiments, the aerosol former material comprises one or more sorbitan esters. Examples of sorbitan esters include sorbitan monolaurate, sorbitan monostearate (Span® 60), sorbitan monooleate (Span® 20), and sorbitan tristearate (Span® 65).

In some embodiments, the aerosol former material comprises one or more fatty acids. Fatty acids may include short-chain, long-chain, saturated, unsaturated, straight chain, or branched chain carboxylic acids. Fatty acids generally include C4 to C28 aliphatic carboxylic acids. Non-limiting examples of short- or long-chain fatty acids include butyric, propionic, valeric, oleic, linoleic, stearic, myristic, and palmitic acids.

In some embodiments, the aerosol former material comprises one or more fatty acid esters. Examples of fatty acid esters include alkyl esters, monoglycerides, diglycerides, and triglycerides. Examples of monoglycerides include monolaurin and glycerol monostearate. Examples of triglycerides include triolein, tripalmitin, tristearate, glycerol tributyrate, and glycerol trihexanoate).

In some embodiments, the aerosol former material comprises one or more waxes. Examples of waxes include carnauba, beeswax, candellila, which are known known to stabilize aerosol particles, improve palatability, or reduce throat irritation.

In some embodiments, the aerosol former material comprises one or more terpenes. As used herein, the term "terpenes" refers to hydrocarbon compounds produced by plants biosynthetically from isopentenyl pyrophosphate. Non-limiting examples of terpenes include limonene, pinene, famesene, myrcene, geraniol, fennel, and cembrene.

In some embodiments, the aerosol former material comprises one or more sugar alcohols. Examples of sugar alcohols include sorbitol, erythritol, mannitol, maltitol, isomalt, and xylitol. Sugar alcohols may also serve as flavor enhancers to certain flavor compounds, e.g., menthol and other volatiles, and generally improve on mouthfeel, tactile sensation, throat impact, and other sensory properties, of the resulting aerosol.

In some embodiments, the aerosol former material comprises glycerol, propylene glycol, 1,3- propanediol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3 -butylene glycol, erythritol, mesoerythritol, 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, propylene carbonate, or a combination of any thereof. In some embodiments, the aerosol former material comprises, consists essentially of, or consists of glycerol. In some embodiments, the aerosol generating material comprises glycerol in an amount by weight from about 15 to about 25% by weight, based on the total wet weight of the aerosol generating material. In some embodiments, the aerosol generating material comprises glycerol in an amount by weight from about 15 to about 25% by weight, based on the total dry weight of the aerosol generating material.

Active ingredient

In some embodiments, the aerosol generating material comprises one or more active ingredients. As used herein, an "active ingredient" refers to one or more substances belonging to any of the following categories: API (active pharmaceutical substances), food additives, natural medicaments, and naturally occurring substances that can have an effect on humans. Example active ingredients include any ingredient known to impact one or more biological functions within the body, such as ingredients that furnish pharmacological activity or other direct effect in the diagnosis, cure, mitigation, treatment, or prevention of disease, or which affect the structure or any function of the body of humans (e.g., provide a stimulating action on the central nervous system, have an energizing effect, an antipyretic or analgesic action, or an otherwise useful effect on the body). In some embodiments, the active ingredient may be of the type generally referred to as dietary supplements, nutraceuticals, "phytochemicals" or "functional foods". These types of additives are sometimes defined in the art as encompassing substances typically available from naturally occurring sources (e.g., botanical materials) that provide one or more advantageous biological effects (e.g., health promotion, disease prevention, or other medicinal properties), but are not classified or regulated as drugs.

Non-limiting examples of active ingredients include those falling in the categories of synthetic organic compounds, proteins and peptides, polysaccharides and other sugars, lipids, inorganic compounds, and nucleic acid sequences, having therapeutic, prophylactic, or diagnostic activity. Non-limiting examples of active ingredients include those falling in the categories of botanical ingredients, stimulants, (e.g., caffeine and guarana), amino acids (e.g., taurine, theanine, phenylalanine, tyrosine, and tryptophan) and/or pharmaceutical, nutraceutical, and medicinal ingredients (e.g., vitamins, such as B6, B12, and C, and/or cannabinoids, such as tetrahydrocannabinol (THC) and cannabidiol (CBD)), antioxidants, and nicotine components. The particular choice of active ingredients will vary depending upon the desired flavor, texture, and desired characteristics of the particular product.

The particular percentages of active ingredients present will vary depending upon the desired characteristics of the particular product. Typically, an active ingredient or combination thereof is present in a total concentration of at least about 0.001% by weight of the aerosol generating material, such as in a range from about 0.001% to about 20%. In some embodiments, the active ingredient or combination of active ingredients is present in a concentration from about 0.1% w/w to about 10% by weight, such as, e.g., from about 0.5% w/w to about 10%, from about 1% to about 10%, from about 1% to about 5% by weight, based on the total weight of the aerosol generating material. In some embodiments, the active ingredient or combination of active ingredients is present in a concentration of from about 0.001%, about 0.01%, about 0.1% , or about 1%, up to about 20% by weight, such as, e.g., from about 0.001%, about 0.002%, about 0.003%, about 0.004%, about 0.005%, about 0.006%, about 0.007%, about 0.008%, about 0.009%, about 0.01%, about 0.02%, about 0.03%, about 0.04%, about 0.05%, about 0.06%, about 0.07%, about 0.08%, about 0.09%, about 0.1%, about 0.2%, about 0.3%, about 0.4%, about 0.5% about 0.6%, about 0.7%, about 0.8%, or about 0.9%, to about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about 10%, about 11%, about 12%, about 13%, about 14%, about 15%, about 16%, about 17%, about 18%, about 19%, or about 20% by weight, based on the total weight of the aerosol generating material. Further suitable ranges for specific active ingredients are provided herein below.

In some embodiments, the active ingredient comprises a nicotine component. By "nicotine component" is meant any suitable form of nicotine (e.g., free base or salt) for providing systemic absorption of at least a portion of the nicotine present. The source of the nicotine may vary, and may be naturally derived or synthetic. Most preferably, the nicotine is naturally occurring and obtained as an extract from a Nicotiana species (e.g., tobacco). The nicotine can have the enantiomeric form .S'-(-)-nicotinc. R-(+)- nicotine, or a mixture of S(-)-nicotine and 7?-(+)-nicotine. Most preferably, the nicotine is in the form of S-(- )-nicotine (e.g., in a form that is virtually all S(-)-nicotine) or a racemic mixture composed primarily or predominantly of .S'-(-)-nicotinc (e.g., a mixture composed of about 95 weight parts .S'-(-)-nicotinc and about 5 weight parts 7?-(+)-nicotine). Most preferably, the nicotine is employed in virtually pure form or in an essentially pure form. Highly preferred nicotine that is employed has a purity of greater than about 95 percent, more preferably greater than about 98 percent, and most preferably greater than about 99 percent, on a weight basis.

Typically, the nicotine component is selected from the group consisting of nicotine free base and a nicotine salt. In some embodiments, nicotine is in its free base form. Nicotine may be tobacco-derived (e.g., a tobacco extract) or non-tobacco derived (e.g., synthetic or otherwise obtained). In various embodiments, the aerosol generating material may comprise a nicotine component. In various embodiments, the aerosol generating material may not comprise a nicotine component. In some embodiments, the aerosol generating material may comprise a non-tobacco-derived nicotine component.

Typically, the nicotine component (calculated as the free base) when present, is in a concentration of at least about 0.001% by weight of the aerosol generating material, such as in a range from about 0.001% to about 10%. In some embodiments, the nicotine component is present in a concentration from about 0.1% w/w to about 10% by weight, such as, e.g., from about 0.1% w/w, about 0.2%, about 0.3%, about 0.4%, about 0.5% about 0.6%, about 0.7%, about 0.8%, or about 0.9%, to about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, or about 10% by weight, calculated as the free base and based on the total weight of the aerosol generating material. In some embodiments, the nicotine component is present in a concentration from about 0.1% w/w to about 3% by weight, such as, e.g., from about 0.1% w/w to about 2.5%, from about 0.1% to about 2.0%, from about 0.1% to about 1.5%, or from about 0.1% to about 1% by weight, calculated as the free base and based on the total weight of the aerosol generating material. These ranges can also apply to other active ingredients noted herein. In some embodiments, the aerosol generating material of the disclosure can be characterized as completely free or substantially free of nicotine components. By "substantially free of nicotine components" is meant that no nicotine has been intentionally added, beyond trace amounts that may be naturally present in e.g., a botanical material or a nicotine-free milled tobacco material. For example, certain embodiments can be characterized as having less than 0.001% by weight of nicotine, or less than 0.0001%, or even 0% by weight of nicotine, calculated as the free base.

In some embodiments, the active ingredient comprises a tobacco extract. In some cases, the aerosol generating material may comprise 5-60 wt% (calculated on a dry weight basis) of tobacco extract. In some cases, the aerosol generating material may comprise from about 5 wt%, 10 wt%, 15 wt%, 20 wt% or 25 wt% to about 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (calculated on a dry weight basis) tobacco extract. For example, the aerosol generating material may comprise 10-50 wt%, 15-40 wt% or 20-35 wt% of tobacco extract. The tobacco extract may contain nicotine at a concentration such that the aerosol generating material comprises 1 wt% 1.5 wt%, 2 wt% or 2.5 wt% to about 10 wt%, 8 wt%, 6 wt%, 5 wt%, 4.5 wt% or 4 wt% (calculated on a dry weight basis) of nicotine. In some embodiments, the aerosol generating component may comprise 1-10 wt%, 2.5-8 wt% or 2-6 wt% nicotine. In some cases, there may be no nicotine in the aerosol generating component other than that which results from the tobacco extract.

In some embodiments, the active ingredient comprises one or more cannabinoids. As used herein, the term "cannabinoid" refers to a class of diverse natural or synthetic chemical compounds that acts on cannabinoid receptors (e.g., CB1 and CB2) in cells that alter neurotransmitter release in the brain. Cannabinoids are cyclic molecules exhibiting particular properties such as the ability to easily cross the blood-brain barrier. Cannabinoids may be naturally occurring (phytocannabinoids) from plants such as cannabis, (endocannabinoids) from animals, or artificially manufactured (synthetic cannabinoids). Cannabis species express at least 85 different phytocannabinoids, and these may be divided into subclasses, including cannabigerols, cannabichromenes, cannabidiols, tetrahydrocannabinols, cannabinols and cannabinodiols, and other cannabinoids, such as cannabigerol (CBG), cannabichromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol (CBN) and cannabinodiol (CBDL), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabinerolic acid, cannabidiolic acid (CBD A), Cannabinol propyl variant (CBNV), cannabitriol (CBO), tetrahydrocannabmolic acid (THCA), and tetrahydrocannabivarinic acid (THCV A).

In some embodiments, the cannabinoid is selected from the group consisting of cannabigerol (CBG), cannabichromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol (CBN) and cannabinodiol (CBDL), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabinerolic acid, cannabidiolic acid (CBDA), Cannabinol propyl variant (CBNV), cannabitriol (CBO), tetrahydrocannabmolic acid (THCA), tetrahydrocannabivarinic acid (THCV A), and mixtures thereof. In some embodiments, the cannabinoid comprises at least tetrahydrocannabinol (THC). In some embodiments, the cannabinoid is tetrahydrocannabinol (THC). In some embodiments, the cannabinoid comprises at least cannabidiol (CBD). In some embodiments, the cannabinoid is cannabidiol (CBD). In some embodiments, the CBD is synthetic CBD. In some embodiments, the cannabinoid (e.g., CBD) is added to the aerosol generating material in the form of an isolate. An isolate is an extract from a plant, such as cannabis, where the active material of interest (in this case the cannabinoid, such as CBD) is present in a high degree of purity, for example greater than 95%, greater than 96%, greater than 97%, greater than 98%, or around 99% purity. In some embodiments, the cannabinoid is an isolate of CBD in a high degree of purity, and the amount of any other cannabinoid in the substrate is no greater than about 1% by weight of the substrate, such as no greater than about 0.5% by weight of the substrate, such as no greater than about 0.1% by weight of the substrate such as no greater than about 0.01% by weight of the substrate. The choice of cannabinoid and the particular percentages thereof which may be present within the disclosed substrate will vary depending upon the desired characteristics of the aerosol generating material.

In some embodiments, the cannabinoid (such as CBD) is present in the aerosol generating material in a concentration of at least about 0.001% by weight of the aerosol generating material, such as in a range from about 0.001% to about 2% by weight of the aerosol generating material. In some embodiments, the cannabinoid (such as CBD) is present in the aerosol generating material in a concentration of from about 0.1% to about 1.5% by weight, based on the total weight of the aerosol generating material. In some embodiments, the cannabinoid (such as CBD) is present in a concentration from about 0.4% to about 1.5% by weight, based on the total weight of the aerosol generating material.

Alternatively, or in addition to the cannabinoid, the active ingredient may include a cannabimimetic, which is a class of compounds derived from plants other than cannabis that have biological effects on the endocannabinoid system similar to cannabinoids. Examples include yangonin, alpha-amyrin or beta-amyrin (also classified as terpenes), cyanidin, curcumin (tumeric), catechin, quercetin, salvinorin A, N- acylethanolamines, and N-alkylamide lipids. Such compounds can be used in the same amounts and ratios noted herein for cannabinoids.

In some embodiments, the active ingredient comprises nicotine and cannabidiol (CBD). In some embodiments, the active ingredient comprises nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol).

Active ingredients suitable for use in the present disclosure can also be classified as terpenes, many of which are associated with biological effects, such as calming effects. Terpenes are understood to have the general formula of (C5H₈)_n and include monoterpenes, sesquiterpenes, and diterpenes. Terpenes can be acyclic, monocyclic or bicyclic in structure. Some terpenes provide an entourage effect when used in combination with cannabinoids or cannabimimetics. Examples include beta-caryophyllene, linalool, limonene, beta-citronellol, linalyl acetate, pinene (alpha or beta), geraniol, carvone, eucalyptol, menthone, iso-menthone, piperitone, myrcene, beta-bourbonene, and germacrene, which may be used singly or in combination.

In some embodiments, the terpene is a terpene derivable from a phytocannabinoid producing plant, such as a plant from the stain of the cannabis sativa species, such as hemp. Suitable terpenes in this regard include so-called "CIO” terpenes, which are those terpenes comprising 10 carbon atoms, and so-called "C15” terpenes, which are those terpenes comprising 15 carbon atoms. In some embodiments, the active ingredient comprises more than one terpene. For example, the active ingredient may comprise one, two, three, four, five, six, seven, eight, nine, ten or more terpenes as defined herein. In some embodiments, the terpene is selected from pinene (alpha and beta), geraniol, linalool, limonene, carvone, eucalyptol, menthone, isomenthone, piperitone, myrcene, beta-bourbonene, germacrene and mixtures thereof. Terpenes and/or cannabinoids may be present in the aerosol generating material as an active ingredient, as an aerosol former material, or as a flavoring component. The amount of terpenes and/or cannabinoids present may vary accordingly based on their intended purpose.

The active ingredient may be a component of the aerosol former material or may be impregnated or otherwise incorporated separately into the aerosol generating material. For example, the impregnation may be performed during preparation of the aerosol generating material, after formation aerosol generating material, or both.

Acid

In some embodiments, the aerosol generating material comprises 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 alphaketo 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.

In some embodiments, 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.

In particular embodiments, the aerosol generating material comprises nicotine and further comprises an acid. In such embodiments, the presence of an acid may stabilize dissolved nicotine species in the slurry from which the aerosol generating material is formed. 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 flavor of the aerosol when nicotine is present. For example, the perceived harshness of the nicotine may be reduced by the presence of the acid.

Flavorant

In some embodiments, the aerosol generating material comprises a flavorant. As used herein, reference to a "flavorant" refers to compounds or components that can be aerosolized and delivered to a user and which impart a sensory experience in terms of taste and/or aroma. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas. Flavorants may be natural or synthetic, and the character of the flavors imparted thereby may be described, without limitation, as fresh, sweet, herbal, confectionary, floral, fruity, or spicy. Some examples of flavorants include, but are not limited to, aloe vera, aniseed, apple, Asian spices, bacopa monniera, basil, bay leaves, beefsteak plant, bergamot, berry, betel, blueberry, bourbon, camphene, cannabis, caraway, cardamom, carvi, cascarilla, cassia, cassis, celery, chamomile, cherry, cherry blossom, chive, cilantro, cinnamon, citrus fruits, clementine, clove, cocoa, coffee, cognac, coriander, cranberry, cucumber, cumin, curcuma, damien, dragon fmit, Drambuie, durian, elderflower, eucalyptus, eugenol, fennel, fenugreek, flax, geranium, gin, ginger, ginkgo biloba, grape, guayusa, hazel, hemp, hibiscus, honeybush, honey essence, hydrangea, Indian spices, jasmine, juniper, khat, lavender, laurel, lemon, lemongrass, lemon balm, lemon oil, lemon peel, licorice, lime, limonene, mace, Japanese white bark magnolia leaf, mango, maple, maijoram, matcha, mate, menthol, mint, myrtle, mulberry, naswar, nutmeg, olive, orange blossom, orange oil, orange skin, oregano, papaya, paprika, peach, peppermint, piment, pimento, pine, rhubarb, rooibos, rosemary, rose hip, rose oil, rum, saffron, sage, sandalwood, scotch, shisha, spearmint, strawberry, tarragon, tea such as green tea or black tea, tequila, terpenes, thyme, tobacco, tropical fruit, turmeric, valerian, vanilla, verbena, wasabi, whiskey, Wintergreen, withania somnifera, yerba mate, yerba santa, ylang-ylang, and combinations thereof.

Flavorants may further include flavor enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, and trigeminal sensates. As used herein, "trigeminal sensate" refers to a flavoring agent which has an effect on the trigeminal nerve, producing sensations including heating, cooling, tingling, and the like. Non-limiting examples of trigeminal sensate flavoring agents include capsaicin, citric acid, menthol, Sichuan buttons, erythritol, and cubebol. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucalyptol or WS-3 (N- ethyl-2-isopropyl-5-methylcyclohexanecarboxamide).

Further non-limiting examples include flavorings and flavor packages of the type and character traditionally used for the flavoring of cigarette, cigar, and pipe tobaccos. See also, Leffingwell et al., Tobacco Flavoring for Smoking Products, R. J. Reynolds Tobacco Company (1972), which is incorporated herein by reference. Flavoring agents may comprise components such as terpenes, terpenoids, aldehydes, ketones, esters, and the like. Syrups, such as high fructose com syrup, also can be employed. Some examples of plant-derived compositions that may be suitable are disclosed in U.S. Pat. No. 9,107,453 and U.S. Pat. App. Pub. No. 2012/0152265 both to Dube et al., the disclosures of which are incorporated herein by reference in their entireties. The selection of such further components is variable based upon factors such as the sensory characteristics that are desired for the smoking article, their affinity for the substrate material, their solubility, and other physiochemical properties. The present disclosure is intended to encompass any such further components that are readily apparent to those skilled in the art of tobacco and tobacco-related or tobacco-derived products. See, e.g., Gutcho, Tobacco Flavoring Substances and Methods, Noyes Data Corp. (1972) and Leffingwell et al., Tobacco Flavoring for Smoking Products (1972), the disclosures of which are incorporated herein by reference in their entireties. It should be noted that reference to a flavorant should not be limited to any single flavorant as described above, and may, in fact, represent a combination of one or more flavorants. Additional flavorants, flavoring agents, additives, and other possible enhancing constituents are described in U.S. Pat. App. No. 15/707,461 to Phillips et al., which is incorporated herein by reference in its entirety.

In some embodiments, the flavorant comprises flavor components of cucumber, blueberry, citms fruits and/or redberry. In some embodiments, the flavor comprises eugenol. In some embodiments, the flavor comprises flavor components extracted from tobacco.

The flavorant may be a component of the aerosol former material or may be impregnated separately into the aerosol generating material. The impregnation may be performed during preparation of the aerosol generating material, after aerosol generating material formation, or both.

The quantity of flavorant present may vary, and when present, is generally less than about 30%, or less than about 20% by weight of the aerosol generating material. For example, a flavorant may be present in a quantity of from about 0.1%, about 0.5%, about 1%, or about 5%, to about 10%, about 20%, or about 30% by weight of the aerosol generating material.

Colorant

In some embodiments, the aerosol generating material comprises a colorant. The addition of a colorant may alter the visual appearance of the aerosol generating material. The presence of colorant may enhance the visual appearance of the aerosol generating material and/or an aerosol generating component comprising the substrate. By adding a colorant to the aerosol generating material, the aerosol generating material may be color-matched to other portions of the aerosol generating component or to other components of an article comprising the aerosol generating material.

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

The colorant 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). Other Components

In some embodiments, the aerosol generating material may further comprise a bum retardant material, conductive fibers or particles for heat conduction/induction, or any combination thereof. One example of a bum retardant material is ammonium phosphate. In some embodiments, other flame/bum retardant materials and additives may be included within the aerosol generating material, and may include organo-phosphoms compounds, borax, hydrated alumina, graphite, potassium, silica, tripolyphosphate, dipentaerythritol, pentaerythritol, and polyols. Other bum retardant materials, such as nitrogenous phosphonic acid salts, mono-ammonium phosphate, ammonium polyphosphate, ammonium bromide, ammonium borate, ethanolammonium borate, ammonium sulphamate, halogenated organic compounds, thiourea, and antimony oxides may also be used. In each aspect of flame-retardant, bum-retardant, and/or scorch-retardant materials used in the aerosol generating material and/or other components (whether alone or in combination with each other and/or other materials), the desirable properties are independent of and resistant to undesirable off-gassing or melting-type behavior. Various manners and methods for incorporating tobacco into smoking articles, and particularly smoking articles that are designed so as to not purposefully bum virtually all of the tobacco within those smoking articles are set forth in U.S. Pat. No. 4,947,874 to Brooks et al.; U.S. Pat. No. 7,647,932 to Cantrell et al.; U.S. Pat. No. 8,079,371 to Robinson et al.; U.S. Pat. No. 7,290,549 to Banegee et al.; and U.S. Pat. App. Pub. No. 2007/0215167 to Crooks et al.; the disclosures of which are incorporated herein by reference in their entireties.

The aerosol generating material may also include conductive fibers or particles for heat conduction or heating by induction. In some embodiments, the conductive fibers or particles may be arranged in a substantially linear and parallel pattern. In some embodiments, the conductive fibers or particles may have a substantially random arrangement. In some embodiments, the conductive fibers or particles may be constmcted of or more of an aluminum material, a stainless-steel material, a copper material, a carbon material, and a graphite material. In some embodiments, one or more conductive fibers or particles with different Curie temperatures may be included in the aerosol generating material to facilitate heating by induction at varying temperatures.

In still other implementations, the aerosol generating material may comprise inorganic fibers of various types (e.g., fiber glass, metal wires/screens, etc.) and/or (organic) synthetic polymers. In various implementations, these "fibrous" materials could be unstructured (e.g., randomly distributed) or structured (e.g., a wire mesh).

Form of aerosol generating material

The form of the aerosol generating material may vary, including such forms as extruded sheet, cast sheet, paper recon sheet, beaded, shredded, or particulate, and the like.

In some embodiments, the aerosol generating material is in sheet form, such as a cast, extruded, or reconstituted paper sheet. In some embodiments, the aerosol generating material in sheet form is a flat sheet. In some embodiments, the flat sheet is layered, for example, in a series of overlapping layers. In some embodiments, the flat sheet may be bunched, crumpled, crimped, and/or otherwise gathered layers. In some embodiments, the flat sheet may further be reduced into cut rag or strips for inserting into the aerosol generating material-containing segment of an aerosol delivery device. The flat sheet may also be gathered or rolled into rod for insertion into the aerosol generating material-containing segment of an aerosol delivery device. In some embodiments, the flat sheet may be shredded. The aerosol generating material in sheet form may be continuous. For example, in a cast or extruded sheet, the aerosol generating material may comprise or be a continuous sheet of material. The sheet may be cut into strips, such as from about 20 to 30 cuts per inch and used as a consumable or a cigarette filler. The sheet may also be shredded to form a shredded sheet and gathered into strands or bundles which are used as a consumable or cigarette as described herein below. The sheet may be in the form of a wrapper, or it may be gathered to form a gathered sheet as described herein below.

The thickness of the aerosol generating material in sheet form may vary. As used herein, the term "thickness" when used in reference to 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 material may have a thickness of about 0.015 mm to about 10 mm. Suitably, the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 5 mm, 3 mm, 2 mm, 1 mm, 0.5 mm or 0.3 mm. In some embodiments, the flat sheet has a thickness from about 0.3 to about 0.8 mm. The aerosol generating material may comprise more than one layer, and the thickness described herein refers to the aggregate thickness of those layers. 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%.

In other embodiments, the aerosol generating material is in beaded form. By "beaded form" is meant that the aerosol generating material is in the form of granules or pellets that can have any of a variety of cross-sectional shapes, including rounded, spherical, ovoid, or irregular shapes. The beaded material is typically flowable such that the beaded material can be readily deposited into an outer housing for use in e.g., an aerosol provision device such as disclosed herein below. In some embodiments, the beads are rounded or spherical. The size of the beads may vary. In some embodiments, the beads are between 8 and 16 mesh (average particle size distribution of 0.149 mm, and a bead weight of 25 to 26 milligrams). In some embodiments, the aerosol generating material in beaded from delivers sharper flavor towards the end of a heating session. In some embodiments, the aerosol generating material in beaded provided superior delivery of eucalyptol when prepared with milled eucalyptus relative to beaded material prepared with eucalyptus extract. Accordingly, in certain embodiments, it may be beneficial to provide the aerosol generating material in beaded form, comprising milled eucalyptus.

Preparation of aerosol generating materials

Preparation of Extruded Sheets

In some embodiments, the aerosol generating material is in extmded sheet form. Generally, the aerosol generating material in extruded sheet form is prepared using extrusion technology. As a non-limiting example description, an extruded sheet disclosed herein may be prepared by combining the individual aerosol generating material ingredients (e.g., milled tobacco, milled botanical or botanical extract, binder, water, and at least a portion of the aerosol former material), to form a dough or agglomerated mass, and extruding the dough. The manner by which the various ingredients are combined may vary. For example, the components noted above, which may be in liquid or dry solid form, can be admixed in a pretreatment step prior to mixture with any remaining components, or simply mixed together with all other liquid or dry ingredients. Any individual component of the aerosol generating material may be added to any other aerosol generating material components, either individually or in any combination. In some embodiments, additional components may be added (e.g., flavorants and the like) to form the dough prior to extrusion.

The various ingredients of the aerosol generating material may be contacted, combined, or mixed together using any mixing technique or equipment known in the art. Any mixing method that brings the aerosol generating material ingredients into intimate contact can be used, such as a mixing apparatus featuring an impeller or other structure capable of agitation. Examples of mixing equipment include casing drums, conditioning cylinders or drums, liquid spray apparatus, conical-type blenders, ribbon blenders, plough shear-type mixers available as FKM130, FKM600, FKM1200, FKM2000 and FKM3000 from Littleford Day, Inc., Hobart mixers, and the like. See also, for example, the types of methodologies set forth in US Pat. Nos. 4,148,325 to Solomon et al.; 6,510,855 to Korte et al.; and 6,834,654 to Williams, each of which is incorporated herein by reference. Manners and methods for formulating mixtures will be apparent to those skilled in the art. See, for example, the types of methodologies set forth in US Pat. No. 4,148,325 to Solomon et al.; US Pat. No. 6,510,855 to Korte et al.; and US Pat. No. 6,834,654 to Williams, US Pat. Nos. 4,725,440 to Ridgway et al., and 6,077,524 to Bolder et al., each of which is incorporated herein by reference.

The dough or agglomerate is then extruded. The extrusion can be carried out using extruders such as screw, auger, injection molding, sieve, basket, roll, and ram-type extruders, extruding the agglomerate through suitably sized and shaped die apertures. In some embodiments, the dough is extruded into a sheet form on a twin-screw extruder using a 0.8 mm thick by 1.25 inches wide die. In some embodiments, the dough is extmded into sheet form, followed by rolling between cylinders (size press). In some embodiments, delivery of certain aromatic components (e.g., D-limonene, anethole and estragole) is superior in extruded sheets prepared from particulate (i.e., milled botanicals) when prepared by a process comprising extruding and rolling relative to those prepared without rolling, those prepared using the paper recon process, or those prepared using botanical extracts. In particular embodiments, delivery of multiple aroma compounds specific to eucalyptus is superior (e.g., more botanical/flavor amplitude and better consistency) for sheets prepared from milled eucalyptus by the extrusion/rolling process. Without wishing to be bound by theory, it is believed that the roll extrusion process, which utilizes less water in the composition and allows the sheets to be dried at lower temperatures, allows retention of more of the volatile aromatic compounds present in the botanical materials. Accordingly, in some embodiments, it may be beneficial to provide the aerosol generating material in extruded sheet form as prepared by a method comprising extruding and rolling a dough comprising the components as described herein above.

The sheets may optionally be dried to remove at least a portion of the liquid content (e.g., water). The final moisture content may be from about 8 to about 21% moisture by weight on a wet basis. Additionally, flavorants, extracts, aerosol former materials, and the like can be added to the sheets after drying. In some embodiments, the cast sheet may be reduced or shredded into cut rag or strips or may be gathered or rolled into a rod.

Preparation of Cast Sheets In some embodiments, the aerosol generating material is in sheet form, and cast sheet technology is used to make the flat sheet. As a non-limiting example description, a band cast sheet disclosed herein may be prepared by combining the individual aerosol generating material ingredients (e.g., milled tobacco, milled botanical or botanical extract, binder, water, and at least a portion of the aerosol former material) to form a slurry (10-20% w/v), which may be cast or dispensed onto a surface (such as, for example, a moving stainless steel belt or mylar carrier surface). The cast slurry may then experience one or more drying and/or doctoring steps such that the result is a relatively consistent thickness cast sheet. Other examples of casting and paper-making techniques are set forth in U.S. Pat. No. 4,674,519 to Keritsis et al.; U.S. Pat. No. 4,941,484 to Clapp et al.; U.S. Pat. No. 4,987,906 to Young et al.; U.S. Pat. No. 4,972,854 to Kiernan et al.; U.S. Pat. No. 5,099,864 to Young et al.; U.S. Pat. No. 5,143,097 to Sohn et al.; U.S. Pat. No. 5,159,942 to Brinkley et al.; U.S. Pat. No. 5,322,076 to Brinkley et al.; U.S. Pat. No. 5,339,838 to Young et al.; U.S. Pat. No. 5,377,698 to Litzinger et al.; U.S. Pat. No. 5,501,237 to Young; and U.S. Pat. No. 6,216,706 to Kumar; the disclosures of which is incorporated herein by reference in their entireties.

The cast sheets may optionally be dried to remove at least a portion of the liquid content (e.g., water). The final moisture content may be from about 8-15% moisture by weight on a wet basis. Additionally, flavorants, extracts, aerosol former materials, and the like can be added to the sheets after drying. In some embodiments, the cast sheet may be reduced into cut rag or strips or may be gathered or rolled into a rod.

Preparation of paper recon sheets

In some embodiments, the aerosol generating material is in sheet form, and is prepared using paper process technology. Paper process technology generally comprises hot water extraction (60-90°C) of a nontobacco botanical material and a tobacco material (e.g., tobacco leaves, stems, scraps, or dust) for a period of time, followed by mechanical separation into pulp materials and extracts. The tobacco or botanical pulp materials are then refined, optionally combined with cellulosic pulp, and formed into a base sheet over a Fourdrinier wire, and the resultant sheet treated with at least a portion of the concentrated extracts mixed with an aerosol former. A typical reconstituted paper process according to a non-limiting embodiment is provided in FIG. 1. With reference to FIG. 1, a botanical material as disclosed herein is extracted with water, forming a spent pulp and aqueous extract. Similarly, tobacco material is extracted to form an extract and tobacco pulp. Generally, the suspension of pulp and water resulting from the extraction of the tobacco and/or botanical material is subjected to a separation step, such as centrifugal and/or fdter separation, forming a weak extract containing solubles and a solids portion containing unrefined fibers for each of the tobacco and botanical materials. The weak tobacco and/or botanical extract may then be concentrated into a >20% solids (w/v) extract, by, for example, vacuum evaporation or other means. Optionally, one or more aerosol former materials as disclosed herein may be added to the extracts, the pulp, or both and thoroughly mixed to obtain a homogenous mix. To the solids may be added water and optionally, pre-pulped wood fibers, and the materials may again be refined to fibrillate the tobacco and botanical material fibers. In some embodiments, a binder as described herein is added. The refined pulp may then be put through a Fourdrinier screen to produce a non-woven web or paper. The web may then be dried to 45-55% moisture content. The concentrated extract, optionally containing aerosol former materials, may then be added back to the web and the web dried down to 8-10% moisture. Optionally, an inert filtering aid may be added to the pulp before web formation on the Fourdrinier screen.

Preparation of Beads

In some embodiments, the aerosol generating material is in beaded form. Generally, the aerosol generating material in beaded form is prepared using a combination of extrusion and spheronization technology. As a non-limiting example description, the beaded aerosol generating material disclosed herein may be prepared by combining the individual aerosol generating material ingredients (e.g., milled tobacco, milled botanical or botanical extract, binder, and at least a portion of the aerosol former material) with water to form an agglomerated mass, extruding the agglomerate into fine fiber-like strands, and then spheronizing the extrudate strands into spheres or other rounded shapes.

The manner by which the various ingredients are combined may vary. For example, the ingredients noted above, which may be in liquid or dry solid form, can be admixed in a pretreatment step prior to mixture with any remaining ingredients, or simply mixed together with all other liquid or dry ingredients. Any individual component of the aerosol generating material may be added to any other aerosol generating material ingredients, either individually or in any combination. In some embodiments, additional ingredients may be added (e.g., fillers, flavorants, and the like) to form the slurry prior to extrusion.

The various components of the aerosol generating material may be contacted, combined, or mixed together using any mixing technique or equipment known in the art. Any mixing method that brings the aerosol generating material ingredients into intimate contact can be used, such as a mixing apparatus featuring an impeller or other structure capable of agitation. Examples of mixing equipment include casing drums, conditioning cylinders or drums, liquid spray apparatus, conical-type blenders, ribbon blenders, plough shear mixers available as FKM130, FKM600, FKM1200, FKM2000 and FKM3000 from Littleford Day, Inc., Hobart mixers, and the like. See also, for example, the types of methodologies set forth in US Pat. Nos. 4,148,325 to Solomon et al.; 6,510,855 to Korte et al.; and 6,834,654 to Williams, each of which is incorporated herein by reference. Manners and methods for formulating mixtures will be apparent to those skilled in the art. See, for example, the types of methodologies set forth in US Pat. No. 4,148,325 to Solomon et al.; US Pat. No. 6,510,855 to Korte et al.; and US Pat. No. 6,834,654 to Williams, US Pat. Nos. 4,725,440 to Ridgway et al., and 6,077,524 to Bolder et al., each of which is incorporated herein by reference.

The agglomerate is then extruded. The extrusion can be carried out using extruders such as screw, sieve, basket, roll, and ram-type extruders, extruding the agglomerate through suitably sized perforated screens. Any suitable extrudate shape may be used. In some embodiments, the agglomerate is extruded into fine fiber-like rods. The extrudate is then processed in a spheronizer or marumerizer (e.g., model Q 120T or QJ 230T, Fuji Paudal, Japan) at a suitable rotation speed (e.g., 1200 RPM) for a suitable time (e.g., 10 minutes). For example, spheronization can be carried out using a spinning friction plate that effects rounding of extrudate particles. The beads may optionally be dried to remove at least a portion of the liquid content (e.g., water). The resulting beads may be dried in fluid bed dryers, apron dryers, rotary dryers, flash dryers, tray dryers or plow mixers. The final moisture content may be from 3-21% moisture by weight on a wet basis.

Following the optional drying, the variously sized beads can be processed through a series of screens to provide the desired size range, such as the sizes noted above (e.g., from about 8 to about 16 mesh). Additionally, flavorants, extracts, aerosol forming materials, and the like can be added to the beads after drying.

Loading the aerosol generating material with aerosol former

In various embodiments, the aerosol generating material may be associated with the aerosol former material by impregnating the aerosol generating material with the aerosol former material during preparation of the aerosol generating material, after formation of the aerosol generating material, or both. For example, in some embodiments, a portion of the aerosol former material (e.g., glycerol or propylene glycol) is added to the slurry used to form the aerosol generating material during e.g., making of a sheet or bead, and a second portion of the aerosol former material (e.g., glycerol or propylene glycol) is added to the sheet or bead as a top dressing (for example, by spraying) to form the final aerosol generating material. In other embodiments, the entirety of the aerosol former material is added to the slurry used to form the aerosol generating material during the making of the aerosol generating material. In some embodiments, further aerosol former materials may be impregnated in or on the aerosol generating material, either by adding further aerosol former materials to the aerosol generating material forming slurry, or as a top dressing to the aerosol generating material. As one of skill will recognize, multiple permutations of methods for loading the aerosol generating material with the aerosol former material are possible, depending on the specific aerosol generating material, form, and the like. Accordingly, any such modifications are contemplated herein.

Aerosol Generating Component

In another aspect is provided an aerosol generating component. The aerosol generating component comprises an aerosol generating material as disclosed herein. The aerosol generating component may take any suitable form, such as a shredded sheet, a corrugated sheet, a sheet which is crimped and gathered into a cylindrical rod, or a plurality of beads. In some embodiments, the aerosol generating component comprises a crimped and gathered sheet or corrugated sheet of the aerosol generating material formed into a rod, the rod having a wrapping material circumscribing the rod.

In some embodiments, the aerosol generating component comprises an aerosol generating material as disclosed herein in flat sheet form. In some embodiments, the flat sheet may further be reduced into cut rag or strips for inserting into the aerosol generating material-containing segment of an aerosol delivery device. In some embodiments, the flat sheet may be bunched, crumpled, crimped, and/or otherwise gathered layers.

In some embodiments, the flat sheet is layered, for example, in a series of overlapping layers. FIG. 2 is an illustration of a perspective schematic view of an aerosol generating component according to a nonlimiting example embodiment of the disclosure. In particular, FIG. 2 illustrates an aerosol generating component 104 having an aerosol generating material 110 that comprises a series of overlapping layers 130 of the aerosol generating material in sheet form 120. With reference to the description above, in the depicted embodiment, the aerosol generating material sheet 120 comprises a layer. In various embodiments, the term "overlapping layers" may also include bunched, crumpled, crimped, and/or otherwise gathered layers in which the individual layers may not be obvious.

FIG. 3 is an illustration of a schematic cross-section view of an aerosol generating component according to a non-limiting example embodiment of the disclosure. In particular, FIG. 3 illustrates an aerosol generating component 104 having an aerosol generating material 110 which comprises a series of overlapping layers 130 of the aerosol generating material sheet 120. In the depicted embodiment, at least a portion of the overlapping layers 130 is substantially surrounded about its outer surface with a first cover layer 132. In various embodiments, the first cover layer 132 may be constructed via a casting process, such as that described in U.S. Pat. No. 5,697,385 to Seymour et al., the disclosure of which is incorporated herein by reference in its entirety. In the depicted embodiment, at least a portion of the overlapping layers 130 and the first cover layer 132 are substantially surrounded about an outer surface with a second cover layer 134. Although the composition of the second cover layer 134 may vary, in the depicted embodiment the second cover layer 134 comprises a metal foil material, such as an aluminum foil material. In other embodiments, the second cover layer may comprise other materials, including, but not limited to, a copper material, a tin material, a gold material, an alloy material, a ceramic material, or other thermally conductive amorphous carbon-based material, and/or any combinations thereof. The depicted embodiment further includes a third cover layer 136, which substantially surrounds the overlapping layers 130, first cover layer 132, and the second cover layer 134, about an outer surface thereof. In the depicted embodiment, the third cover layer 136 comprises a paper material, such as a conventional cigarette wrapping paper. In various embodiments, the paper material may comprise rag fibers, such as non-wood plant fibers, and may include flax, hemp, sisal, rice straw, and/or esparto fibers.

In some embodiments, the aerosol generating component 104 comprises the aerosol generating material 110, optionally in sheet form 120, and further comprises an additional tobacco material (e.g., reconstituted or lamina tobacco). For avoidance of doubt, this additional tobacco material is separate and distinct from the tobacco material present in the aerosol generating material 110 and does not form part of the aerosol generating material 110. Instead, this additional tobacco material is physically combined with the aerosol generating material 110. In some embodiments, the aerosol generating component 104 comprises from about 10 to about 100 wt% of the aerosol generating material 110, with the remainder of the component comprising or consisting of tobacco material. In some embodiments, the tobacco material is present in the aerosol generating component 104 in an amount of from about 50 to 90 wt%, or about 60 to 90 wt%, or about 70 to 90 wt%, or about 80 to about 90 wt% of the aerosol generating component 104. In some embodiments, the aerosol generating material 114 is present in the aerosol generating component 104 in an amount of about 5 to 40 wt%, 5 to 30 wt%, 5 to 25 wt%, or 10 to 25 wt% or 10 to 20 wt%. In some embodiments, the aerosol generating component 104 consists of, or consists essentially of the aerosol generating material 110 and the tobacco material. Any suitable form of tobacco material may be used, such as tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. The tobacco material may comprise one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stem, reconstituted tobacco and/or tobacco extract.

In some embodiments, the aerosol generating material 110 is present as a shredded sheet which is blended with tobacco material. In some embodiments, the aerosol generating material 110 is present as a plurality of beads which are blended with tobacco material. In some embodiments, the tobacco material is fine-cut and/or shredded, e.g. the aerosol generating material 110 and tobacco material are in a similar form. In some embodiments, the tobacco material comprises reconstituted tobacco, tobacco lamina, fine-cut tobacco, cut-rag tobacco, or a combination thereof. In some embodiments, the tobacco material is Charlotte cut tobacco.

In some embodiments, the aerosol generating material 110 is shredded and blended with other materials, such as a support, instead of or in addition to tobacco, to form the aerosol generating component 104. Suitable supports are described further hereinbelow.

Support

In some embodiments, the aerosol generating material as described herein may be present on or in a support to form a substrate (which in some embodiments is synonymous with the term "consumable"). In such embodiments, the support functions as a scaffold on which the aerosol generating material layer is formed, 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 embodiments, 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 embodiments, the support may comprise or consist of a tobacco material, such as a sheet of reconstituted tobacco. In some embodiments, the support may be formed from materials selected from metal foil, paper, cardboard, wood or combinations thereof. In some embodiments, the support comprises paper. In some embodiments, the support itself may be a laminate structure comprising layers of materials selected from the preceding lists. In some embodiments, the support may also function as a flavor support. For example, the support may be impregnated with a flavorant or with tobacco extract.

The thickness of the support layer may vary. In some embodiments, the thickness of the support layer may be in the range of about 10 pm, 15 pm, 17 pm, 20 pm, 23 pm, 25 pm, 50 pm, 75 pm or 0.1 mm to about 2.5 mm, 2.0 mm, 1.5 mm, 1.0 mm or 0.5 mm. The support may comprise more than one layer, and the thickness described herein refers to the aggregate thickness of those layers.

In some embodiments, 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 embodiments, 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 embodiments, the surface of the support that abuts the aerosol generating material may be porous. For example, in some embodiments, 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 some particular embodiments, 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 embodiment, 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 embodiments, the support is formed from or comprises metal foil, such as aluminum 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 20 pm, such as from about 1 pm to about 10 pm, suitably about 5 pm. In some embodiments, the support may have a thickness of between about 0.017 mm and about 2.0 mm, suitably from about 0.02 mm, 0.05 mm or 0.1 mm to about 1.5 mm, 1.0 mm, or 0.5 mm.

Consumable

In another aspect of the disclosure is provided 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 an aerosol generating component as described herein (e.g., 104, comprising an aerosol generating material 110, such as an aerosol generating material in sheet form 120). 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 component 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.

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 delivery system described herein can be implemented as a combustible aerosol provision system or a non-combustible aerosol provision system.

Combustible aerosol provision system

An aspect of the invention provides a combustible aerosol provision system where a constituent aerosol generating material (e.g., 110, such as an aerosol generating material in sheet form 120) of the aerosol provision system (or component thereof) is combusted or burned during use in order to facilitate delivery of at least one substance to a user. In some embodiments, the delivery system is a combustible aerosol provision system, such as a system selected from the group consisting of a cigarette, a cigarillo and a cigar.

Non-combustible aerosol provision device

An aspect of the invention provides a non-combustible aerosol provision system comprising an article (i.e., an aerosol generating material (e.g., 110 or 120), component (e.g., 104), or consumable) as described herein and a heater which is configured to heat but not bum 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 component 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 4 mm, 3 mm, 2 mm or 1 mm from the heater. In some cases, the material is disposed between about 0.010 mm and 2.0 mm from the heater, suitably between about 0.02 mm and 1.0 mm, suitably 0.1 mm to 0.5 mm. 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 bum the aerosol generating article, and thus the aerosol generating component. 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 produce 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-bum device. A heat-not-bum device is disclosed in International Patent Application Publication No. WO2015/062983, 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 component 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 components 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 component. An electronic tobacco hybrid device is disclosed in International Patent Application Publication No. WO2016/135331, 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 volatilized components thereby cooling the aerosol.

The ventilation enhances the generation of visible heated volatilized components from the article when it is heated in use. The heated volatilized components are made visible by the process of cooling the heated volatilized components such that supersaturation of the heated volatilized components occurs. The heated volatilized components then undergo droplet formation, otherwise known as nucleation, and eventually the size of the aerosol particles of the heated volatilized components increases by further condensation of the heated volatilized components and by coagulation of newly formed droplets from the heated volatilized components.

In some cases, the ratio of the cool air to the sum of the heated volatilized components and the cool air, known as the ventilation ratio, is at least 15%. A ventilation ratio of 15% enables the heated volatilized components to be made visible by the method described above. The visibility of the heated volatilized components enables the user to identify that the volatilized 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 volatilized components. In some cases, the ventilation ratio may be at least 60% or 65%.

In some cases, the aerosol generating component may be included in the article/assembly in sheet form as described herein above. In some cases, the aerosol generating component may be included as a planar sheet. In some cases, the aerosol generating component 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 rod or tube), each as described herein above. 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 component 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 cases, the first and second aerosol generating materials described herein may both be formed as a sheet and then shredded and mixed together to form an aerosol generating component. Said component may then be incorporated into the article. In some cases, the shredded sheets may also be mixed with cut rag tobacco and incorporated into the article.

In some embodiments, the aerosol generating material is formed as a foam on a support. The aerosol generating foam may be a continuous foam or a discontinuous foam, such as an arrangement of discrete portions of foam on a support.

FIG. 4 and FIG. 5 are a partially cut-away section view and a perspective view, respectively, of an example of an aerosol generating article 101 according to non-limiting embodiments of the disclosure. 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 FIGS. 8 to 10, described below. In use, the article 101 may be removably inserted into the device shown in FIG. 7 at an insertion point 20 of the device 1.

Referring to FIG. 4 and FIG. 5, the article 101 of one example is in the form of a substantially cylindrical rod that includes a body of aerosol generating component 103 and a filter assembly 105 in the form of a rod. The aerosol generating component 103 comprises an aerosol generating material as described herein (e.g., 110). In some embodiments, it may be included in sheet form (e.g., 120). In some embodiments it may be included in the form of a shredded sheet. In some embodiments, the aerosol generating component 103 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 component 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 component 103 between the body of aerosol generating component 103 and the filter segment 109, such that the cooling segment 107 is in an abutting relationship with the aerosol generating component 103 and the filter segment 103. In other examples, there may be a separation between the body of aerosol generating component 103 and the cooling segment 107 and between the body of aerosol generating component 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 37 mm and 45 mm, more preferably, the total length of the filter assembly 105 is 41 mm.

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

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

An axial end of the body of aerosol generating component 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 component 103.

The body of aerosol generating component 103 is joined to the fdter 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 component 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 42 mm and 50 mm, suitably of 46 mm.

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 volatilized components generated from the body of aerosol generating component 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 0.29 mm.

The cooling segment 107 provides a physical displacement between the aerosol generating component 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 volatilized component entering a first end of the cooling segment 107 and a heated volatilized 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 volatilized component entering a first end of the cooling segment 107 and a heated volatilized 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 component 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 component 103 and the heating elements of the device 1, then the temperature sensitive filter segment 109 may 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 15 mm. In one example, the length of the cooling segment 107 is between 20 mm and 30 mm, more particularly 23 mm to 27 mm, more particularly 25 mm to 27 mm, suitably 25 mm.

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 volatilized compounds from heated volatilized 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 volatilized components without depleting the quantity of the heated volatilized 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 flavorant or aerosol former material.

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 an 8Y15 grade of filter tow material, which provides a filtration effect on the heated volatilized material, whilst also reducing the size of condensed aerosol droplets which result from the heated volatilized material.

The presence of the filter segment 109 provides an insulating effect by providing further cooling to the heated volatilized 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 6 mm to 10 mm 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 volatilized 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 0.29 mm. In one example, the length of the mouth end segment 111 is between 6 mm to 10 mm, suitably 8 mm.

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 FIG. 6 and 7, there are shown a partially cut-away section and perspective views of an example of an article 301 having an aerosol generating component 303, filter assembly 305, a cooling segment 307, a filter segment 309, a mouth end segment 311, a proximal end 313, distal end 315, and a ventilation region 317. The reference signs shown in FIGS. 6 and 7 are equivalent to the reference signs shown in FIGS. 3 and 4, but with an increment of 200.

In the example of the article 301 shown in FIGS. 6 and 7, 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 500 pm in diameter. In one example, an axial separation between rows of ventilation holes 317 is between 0.25 mm and 0.75 mm, suitably 0.5 mm.

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 11 mm from the proximal end 313 of the article, suitably between 17 mm and 20 mm 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 17 mm and 20 mm 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 FIGS. 9 and 10. 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 FIGS. 9 and 10, 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 FIGS. 8 to 10 in more detail, there is shown an example of a device 1 arranged to heat aerosol generating component to volatilize at least one component of said aerosol generating component, 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 component.

Referring to FIGS. 8 and 9, 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 unibody 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 unibody sleeve 11, to permit easy access to the interior of the device 1 or may be "permanently” fixed to the unibody 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 molding, and the uni-body sleeve 11 is made of aluminum, 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 component 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 component 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 component in the article (as discussed, to volatilize the aerosol generating material without causing the aerosol generating component to bum).

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. Each heating element may be annular or tubular, or at least part-annular or part-tubular around its circumference. In an example, each heating element may be a thin film heater. In another example, 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 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 component 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. 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 minimize 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 59 may further comprise 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 vapors 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 FIGS. 8 to 10. Referring particularly to FIG. 9, in one example, the body of aerosol generating component 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 volatilize at least one component of the aerosol generating component from the body of aerosol generating component 103, 303.

The primary flow path for the heated volatilized materials from the body of aerosol generating component 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, 311 to the user. In one example, the temperature of the heated volatilized components that are generated from the body of aerosol generating component is between 60°C and 250°C, which may be above the acceptable inhalation temperature for a user. As the heated volatilized material travels through the cooling segment 107, 307, it will cool and some volatilized materials will condense on the inner surface of the cooling segment 107, 307.

In the examples of the article 301 shown in FIGS. 6 and 7, 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 volatilized components to provide additional cooling to the heated volatilized components.

Although an aerosol deliver device and/or an aerosol generating component according to the present disclosure may take on a variety of embodiments, as discussed in detail above, the use of the aerosol delivery device and/or aerosol generating component by a consumer will be similar in scope. The foregoing description of use of the aerosol delivery device and/or aerosol generating component is applicable to the various embodiments described through minor modifications, which are apparent to the person of skill in the art in light of the further disclosure provided herein. The description of use, however, is not intended to limit the use of the articles of the present disclosure but is provided to comply with all necessary requirements of disclosure herein.

Method of generating an aerosol

In another aspect of the disclosure is provided a method of generating an aerosol using a noncombustible 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 from about 220°C to about 280°C during 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.

Many modifications and other embodiments of the disclosure will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the disclosure is not to be limited to the specific embodiments disclosed herein and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

EXAMPLES

Aspects of the present invention are more fully illustrated by the following examples, which are set forth to illustrate certain aspects of the present invention and are not to be construed as limiting thereof.

Example 1. Extruded sheet aerosol generating materials with milled botanical and milled tobacco (screw extrusion process)

A total of 8 batches (20 lbs each) of extruded sheet aerosol generating materials comprising the ingredients set forth in Table 1 below were prepared in a matrix format using either regular tobacco or nonnicotine tobacco (milled tobacco that has been processed to extract substantially all of the nicotine), and fennel, rooibos, star anise, or eucalyptus as the milled botanical. The actual ingredients and percentages were varied depending on the desired properties of the final product.

The milled tobacco, milled botanical, and carboxymethylcellulose were weighed into a mixer (model FM 130 D Littleford precision plough mixer) and mixed on medium speed (100-125 rpm) for 5 minutes. Water was added, followed by glycerol and the combination was mixed on medium speed for approximately one minute, or until pea-like clumps were observed. The chopper motor was run for approximately 5 seconds, then the mixture was mixed at low speed and discharged into a receiver. The mixture was transferred to the extrusion hopper and subsequently fed and extruded into sheet form using a twin-screw extruder (model ZSK25 Coperion) with a 0.3 mm thick by 1.25 inches wide die. The extruder was run at the following settings: a. screw speed 100 RPM b. 135°F (11 barrel zones) c. die plate A: 140°F d. exit die plate B: 130°F e. liquid pump 4 Ib/hr (mixed water and glycerol) f. feeder: 12 Ib/hr (mixture of dry ingredients) g. dryer temperature post extrusion: 170°F The extruded sheets were then laid flat on racks and dried to 15 +/-3% moisture content.

Table 1 : Formulation of milled botanical extruded sheet embodiments

Example 2. Extruded sheet aerosol generating materials with botanical extract and milled tobacco (screw extrusion process)

A total of 8 batches (10 lbs each) of extruded sheet aerosol generating materials comprising the ingredients set forth in Table 2 below were prepared as described for Example 1 but using a 0.8 mm thick by 1.25 inches wide die. The sheets were prepared in a matrix format using either regular tobacco or nonnicotine tobacco (milled tobacco that has been processed to extract substantially all of the nicotine), and fennel, rooibos, star anise, or eucalyptus as the botanical extract. The actual ingredients and percentages were varied depending on the desired properties of the final product. The extruded sheets were then laid flat on racks and dried to 18 +/-3% moisture content.

Table 2: Formulation of milled botanical extruded sheet embodiments

Example 3. Extruded sheet aerosol generating materials with milled botanical and milled tobacco (roll process)

A total of 8 batches (10 lbs each) of extruded sheet aerosol generating materials comprising the ingredients set forth in Table 3 below were prepared in a matrix format using either regular tobacco or nonnicotine tobacco (milled tobacco that has been processed to extract substantially all of the nicotine), and fennel, rooibos, star anise, or eucalyptus as the milled botanical. The actual ingredients and percentages were varied depending on the desired properties of the final product.

The milled tobacco, botanical extract, carboxymethylcellulose, and glycerol were combined, along with enough water to make up 12-15% w/v of the combined composition. After mixing, the mixture was discharged into a receiver and extruded into sheet form, followed by rolling between cylinders (size press), providing 140-180 mm thick sheets. The sheets were dried at low temperature (up to 60°C) to a final moisture content of about 10-18%.

Table 3 : Formulation of milled botanical extruded sheet embodiments

Example 4. Extruded sheet aerosol generating materials with botanical extract and milled tobacco (roll process)

A total of 8 batches (10 lbs each) of extruded sheet aerosol generating materials comprising the ingredients were prepared according to the procedure of Example 3, but using the formulation set forth in Table 4. The batches were prepared in a matrix format using either regular tobacco or non-nicotine tobacco (milled tobacco that has been processed to extract substantially all of the nicotine), and fennel, rooibos, star anise, or eucalyptus as the botanical extract. The actual ingredients and percentages were varied depending on the desired properties of the final product.

Table 4: Formulation of botanical extract extruded sheet embodiments

Example 5. Cast sheet aerosol generating materials s with milled botanical and milled tobacco

A total of 8 batches (20 lb each) of cast sheet aerosol generating materials comprising the ingredients set forth in Table 5 were prepared in a matrix format using either regular tobacco or non-nicotine tobacco (milled tobacco that has been processed to extract substantially all of the nicotine), and fennel, rooibos, star anise, or eucalyptus as the milled botanical. The actual ingredients and percentages were varied depending on the desired properties of the final product.

A binder solution (2% w/v) was first prepared by hydrating CMC in IL of water in a high shear mixer for 15 min. An equivalent amount of pre-refined cellulose pulp slurry (4% w/v) was then added and high-shear mixed for 5 min. Then milled tobacco and milled botanical were slowly added and mixed for 10 min. Finally, glycerol was added and mixed for another 5 min to form a final slurry. The slurry was then cast onto a 22 -inch-wide stainless steel conveyer belt using a casting knife set at 1-3 mm gap opening. The cast material or film was subsequently dried into a flat sheet by conveying the film through a 200 feet convection tunnel dryer, comprising multiple heated zones (e.g., ranging from 80-100°C) to a final moisture content of about 8-12%%

Table 5: Formulation of milled botanical cast sheet embodiments

Example 6. Beaded aerosol generating materials with milled botanical and milled tobacco

A total of 8 batches (10 lbs each) of beaded aerosol generating materials comprising the ingredients set forth in Table 6 were prepared in a matrix format (using either regular tobacco or non-nicotine tobacco (milled tobacco that has been processed to extract substantially all of the nicotine), and fennel, rooibos, star anise, or eucalyptus as the milled botanical). The actual ingredients and percentages can be varied depending on the desired properties of the final product.

The milled tobacco, milled botanical, and carboxymethylcellulose were weighed into a mixer (model FM 130 D Littleford precision plough mixer) and mixed on medium speed for 5 minutes. Water (amount dependent on the binder used) was added, followed by glycerol and the combination mixed on medium speed for approximately one minute, or until pea-like clumps were observed. The chopper motor was run for approximately 5 seconds, then the mixture was mixed at low speed and discharged into a receiver. The mixture was extruded using a 1.5 mm doomed screen die on an Osaka Multi-Gran MG-55 extruder (Fuji Paudal Co., Ltd.), resulting in multi-grain (hair-like) shaped rods. The extrudate rods were subsequently transferred into a model QJ-230T-2 Fuji Paudal Co. Ltd. laboratory marumerizer. The marumerizer rotating bowl was used to reshape the rods into rounded beads. The rods were spheronized (time may vary from about 19 seconds to about 2 minutes) to give beads, which were dried for 30-45 minutes at 65°C, providing a target moisture content of about 6% +/-3%. The resulting beads were screened to between 8 and 16 mesh (average particle size distribution was 0.149 mm, and bead weight was 25 to 26 milligrams).

Table 6: Formulation of beaded embodiments comprising milled botanical Example 7. Beaded aerosol generating materials with botanical extract and milled regular tobacco

A total of 4 batches (10 lbs each) of beaded aerosol generating materials comprising the ingredients set forth in Table 7 were similarly prepared as described for Example 6, except that milled botanical was replaced with botanical extract.

Table 7: Formulation of beaded embodiments comprising botanical extract (regular tobacco)

Example 8. Beaded aerosol generating materials with botanical extracts and milled nonnicotine tobacco

A total of 4 batches (10 lbs each) of beaded aerosol generating materials comprising the ingredients set forth in Table 8 were prepared as described for Example 7, except that the milled tobacco was replaced with non-nicotine tobacco.

The beads were then dried for 30-45 minutes at 65°C, providing beads with a target moisture content of about 6%, +/-3%.

Table 8: Formulation of beaded embodiments comprising botanical extract (non-nicotine tobacco)

Example 9. Paper recon aerosol generating materials with milled eucalyptus and milled tobacco

An aerosol generating material was prepared using the formulation of Table 9. A reconstituted sheet using traditional tobacco and botanical materials as input was prepared according to the following procedure. Flue-cured tobacco stem and lamina components were hammer milled to less than 5 mm particles to improve extraction efficiency. Milled stems and lamina were then mixed to provide a ratio of 20% tobacco stems and 80% tobacco lamina. Botanical eucalyptus was similarly milled to less than 5 mm particles as described above. In separate vessels, the milled tobacco stems and lamina as well as the milled Eucalyptus were then mixed with water to form slurries (e.g., about 10% w/v). Each slurry was heated to and held at 60-70°C for up to 2.0 hours with constant stirring. Each slurry was then separated by mechanical means (centrifugation and/or filtration) into its solid/fiber (spent material) and weak extract liquor (WEL) components. Both fiber components were subsequently mixed with cellulose pulp (wood pulp) and refined into a pulp using a rotatory disc refiner and then further diluted into a 1% (w/v) pulp. This pulp was drained over a Fourdrinier wire to form a base web/mat or base sheet.

Separately, the tobacco WEL was vacuum evaporated at 60-65° C and 55 psi to yield a concentrated extract liquor (CEL) of 25-30% (w/v) solids. The CEL was then mixed with the botanical Eucalyptus WEL and glycerol in an amount of about 15-20% by weight, based on the weight of the original infeed materials. The CEL was then applied or sprayed back onto the base web to yield a 42% hot water solubles content in the final sheet. As used herein, the term “hot water solubles (HWS)” generally refers to the amount of tobacco and botanical material extract contained within the final sheet and typically contains sugars, proteins, amino acids, organic acids, polyphenols, flavonoids, waxes, TSNAs, nitrate, nitrite, traces metals, heavy metals and added glycerol. Next, the final sheet was tunnel dried at 300-325° C for about 5-10 min.

The final aerosol generating material comprised about 20% glycerol by total weight of the aerosol generating material.

Table 9: Formulation of paper recon embodiments comprising milled eucalyptus

Example 10. Paper recon aerosol generating materials with milled star anise and milled tobacco

An aerosol generating material was prepared as in Example 9 but using the formulation of Table 10 (milled eucalyptus was replaced with milled star anise). The final aerosol generating material comprised glycerol at about 20% by weight, based on the total weight of the aerosol generating material.

Table 10: Formulation of paper recon embodiments comprising milled anise

Example 11. Paper recon aerosol generating materials with eucalyptus pulp and milled tobacco

An aerosol generating material was prepared as in Example 9 but using the formulation of Table 11 (milled eucalyptus was replaced with previously extracted eucalyptus fiber. Hence, no WEL was generated from the botanical component). The final aerosol generating material comprised glycerol at about 20% by weight, based on the total weight of the aerosol generating material.

Table 11: Formulation of paper recon embodiments comprising eucalyptus extract

Example 12. Paper recon aerosol generating materials with star anise pulp and milled tobacco

An aerosol generating material was prepared as in Example 11, but using the formulation of Table 12 (eucalyptus fiber was replaced with star anise fiber). The final aerosol generating material comprised glycerol at about 20% by weight, based on the total weight of the aerosol generating material.

Table 12: Formulation of paper recon embodiments comprising star anise extract

Example 13. Preparation of aerosol generating components

The aerosol generating materials of Examples 1-12 were converted into aerosol generating consumables. Each consumable component was prepared by blending 30% by weight of the aerosol generating material (Examples 13A-13HHH, shown below in Table 13) with 70% of a separate paper reconstituted tobacco (Control, no botanical used). Samples of the Control reconstituted tobacco sheet and aerosol generating materials of Examples 1-5 and 9-12 were each, separately cut/converted into cut filler tobacco (1-2 x 4-6 mm strips), blended at an 70/30 ratio, and incorporated into consumables (conventional-like cigarette). Samples of the cut filler Control tobacco were similarly blended 70/30 with aerosol generating materials from Example 6-8 to make conventional-like cigarette consumables.

Table 13, Summary of aerosol generating component compositions

Example 14. Aerosol chemistry evaluations Consumables containing aerosol generating components of Example 13 having eucalyptus and star anise as the botanical material (milled and extract; 32 samples as listed in Table 14) were evaluated for aerosol chemistry under both ISO and HCI-m smoke regimes (Table 15). All samples were conditioned under ISO standards for 48 hours and smoked on Hyper devices using the base profile. Smoke samples thus obtained were analyzed for concentrations of formaldehyde, acetaldehyde, acrolein, and tobacco-specific nitrosamines (TSNA's).

Table 14, Aerosol generating components evaluated

Table 15, Smoke regimes

Results

The emissions data collected under the smoke regimens showed that substrates comprising botanical extracts provided higher levels of formaldehyde, acetaldehyde, and TSNA’s than those comprising milled botanical materials. On average, substrates comprising non-nicotine tobacco contributed to an increase in NNK values as seen in both eucalyptus and star anise samples. On average, with the exception of acrolein, toxicant levels were reduced in paper recon substrates when compared to other substrate types (acrolein levels were reduced in the various substrate samples evaluated (cast sheet, extruded sheet, beaded; both eucalyptus and star anise) relative to the paper recon substrates).

Claims

CLAIMS What is claimed is:

1. An aerosol generating material for use in an aerosol delivery device, the aerosol generating material comprising: a tobacco material in particulate form, present in the aerosol generating material in an amount from about 20% to about 90% by weight, based on the total weight of the aerosol generating material; a non-tobacco botanical material selected from the group consisting of eucalyptus, rooibos, star anise, fennel, and combinations thereof; from 0 to about 25% by weight of a binder, based on the total weight of the aerosol generating material; and an aerosol former material.

2. The aerosol generating material of claim 1, wherein the non-tobacco botanical material is in particulate form and is present in an amount in a range from about 5 to about 30% by weight, based on the total weight of the aerosol generating material.

3. The aerosol generating material of claim 1, wherein the non-tobacco botanical material is in the form of an extract and is present in an amount in a range from about 0.5 to about 3% by weight, based on the total weight of the aerosol generating material.

4. The aerosol generating material of any one of claims 1-3, wherein the binder is selected from the group consisting of alginates, seaweed hydrocolloids, cellulose ethers, starches, gums, dextrans, carrageenan, povidone, pullulan, zein, and combinations thereof.

5. The aerosol generating material of any one of claims 1-4, wherein the binder is a cellulose ether selected from the group consisting of methylcellulose, hydroxypropylcellulose, hydroxypropylmethylcellulose, hydroxyethyl cellulose, carboxymethylcellulose, and combinations thereof.

6. The aerosol generating material of any one of claims 1-5, wherein the binder is carboxymethylcellulose.

7. The aerosol generating material of any one of claims 1-6, wherein the aerosol former material is selected from the group consisting of water, a polyhydric alcohol, a polysorbate, a sorbitan ester, a fatty acid, a fatty acid ester, a wax, a cannabinoid, a terpene, a sugar alcohol, and combinations thereof.

8. The aerosol generating material of any one of claims 1-7, wherein the aerosol former material comprises a polyhydric alcohol.

9. The aerosol generating material of claim 8, wherein the polyhydric alcohol is present in an amount from about 15 to about 25% by weight, based on the total weight of the aerosol generating material.

10. The aerosol generating material of claim 8, wherein the polyhydric alcohol is selected from the group consisting of glycerol, propylene glycol, 1,3 -propanediol, diethylene glycol, triethylene glycol, triacetin, and combinations thereof.

11. The aerosol generating material of any one of claims 1-10, in the form of an extruded sheet comprising: from about 20 to about 70% by weight of the tobacco material in particulate form, based on the total weight of the aerosol generating material; from about 20 to about 30% by weight of the non-tobacco botanical material, present in particulate form, based on the total weight of the aerosol generating material; and the binder in an amount from about 6 to about 25% by weight, based on the total weight of the aerosol generating material.

12. The aerosol generating material of claim 11, wherein the tobacco material is substantially free of nicotine, and is present in an amount by weight from about 20 to about 35%, based on the total weight of the aerosol generating material

13. The aerosol generating material of any one of claims 1-10, in the form of an extruded sheet comprising: from about 25 to about 70% by weight of the tobacco material in particulate form, based on the total weight of the aerosol generating material; the non-tobacco botanical material is in the form of an extract, and is present in an amount in a range from about 1.5 to about 3% by weight, based on the total weight of the aerosol generating material; and the binder in an amount from about 6 to about 25% by weight, based on the total weight of the aerosol generating material.

14. The aerosol generating material of any one of claims 1-10, in the form of a cast sheet comprising: from about 24 to about 36% by weight of the tobacco material in particulate form, based on the total weight of the aerosol generating material; from about 20 to about 30% by weight of the non-tobacco botanical material, present in particulate form, based on the total weight of the aerosol generating material; and the binder in an amount from about 8 to about 12% by weight, based on the total weight of the aerosol generating material.

15. The aerosol generating material of any one of claims 1-10, in the form of a reconstituted paper sheet comprising: from about 70 to about 90% by weight of the tobacco material in particulate form, based on the total weight of the aerosol generating material; and from about 5 to about 15% by weight of the non-tobacco botanical material, present in particulate form, based on the total weight of the aerosol generating material.

16. The aerosol generating material of any one of claims 1-10, in the form of a reconstituted paper sheet comprising: from about 70 to about 90% by weight of the tobacco material in particulate form, based on the total weight of the aerosol generating material; and the non-tobacco botanical material is in the form of an extract and is present in an amount in a range from about 0.5 to about 1.5% by weight, based on the total weight of the aerosol generating material.

17. The aerosol generating material of any one of claims 1-10, in beaded form comprising: from about 32 to about 72% by weight of the tobacco material in particulate form, based on the total weight of the aerosol generating material; from about 16 to about 24% by weight of the non-tobacco botanical material, present in particulate form, based on the total weight of the aerosol generating material; and the binder in an amount from about 0.6 to about 1% by weight, based on the total weight of the aerosol generating material.

18. The aerosol generating material of any one of claims 1-10, in beaded form comprising: from about 32 to about 72% by weight of the tobacco material in particulate form, based on the total weight of the aerosol generating material; the non-tobacco botanical material is in the form of an extract, and is present in an amount in a range from about 1.5 to about 3% by weight, based on the total weight of the aerosol generating material; the binder in an amount from about 0.6 to about 1% by weight, based on the total weight of the aerosol generating material; and further comprising rice flour in an amount from about 16 to about 24% by weight, based on the total weight of the aerosol generating material.

19. The aerosol generating material of any one of claims 1-19, wherein a moisture content of the aerosol generating material is from about 12 to about 21% by weight, based on the total weight of the aerosol generating material.

20. The aerosol generating material of any one of claims 1-20, wherein the tobacco material is substantially free of nicotine.

21. The aerosol generating material of any one of claims 1-20, wherein the aerosol generating material is substantially free of nicotine.

22. An aerosol generating component comprising the aerosol generating material of any one of claims 1- 21.

23. The aerosol generating component of claim 22, wherein the aerosol generating material is blended with an additional tobacco material which is different in character from the particulate tobacco material comprising the aerosol generating material.

24. The aerosol generating component of claim 23, wherein the additional tobacco material comprises reconstituted tobacco, tobacco lamina, fine-cut tobacco, cut-rag tobacco, or a combination thereof.

25. A consumable for use in a non-combustible aerosol provision device, the consumable comprising the aerosol generating component of claim 22.

26. A non-combustible aerosol provision system comprising the consumable of claim 25 and a noncombustible aerosol provision device, the non-combustible aerosol provision device comprising an aerosol generating device arranged to generate aerosol from the consumable when the consumable is used with the non-combustible aerosol provision device.

27. A combustible aerosol provision system comprising the consumable of claim 25 and a combustible aerosol provision device.