EP4678014A1

EP4678014A1 - An aerosol generating material

Info

Publication number: EP4678014A1
Application number: EP24187804.0A
Authority: EP
Inventors: Anthony Cunningham; Daniel Arthur
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2024-07-10
Filing date: 2024-07-10
Publication date: 2026-01-14
Also published as: WO2026013394A1; GB202413895D0

Abstract

An extruded aerosol generating material comprising: a fibrous material, an active and/or a flavourant, and an additive for scavenging carbonyls; and rods, articles, and systems comprising the material; and methods of making the material.

Description

Technical Field

The present application relates to aerosol generating materials, articles comprising the aerosol generating material for use in non-combustible aerosol provision devices, and non-combustible aerosol provision systems comprising articles and devices.

Background

Aerosol-generating systems produce an aerosol during use, which is inhaled by a user. For example, tobacco heating devices heat an aerosol-generating material such as tobacco to form an aerosol by heating, but not burning, the aerosol-generating material.

Summary

According to a first aspect, there is described an extruded aerosol generating material comprising: a fibrous material, an active and/or a flavourant, and an additive for scavenging carbonyls.
According to a second aspect, there is described an aerosol generating material comprising: a non-tobacco botanical material, an active and/or flavourant, and a binder system comprising a first binder and a second binder, wherein a ratio of the non-tobacco botanical material to the binder system is from about 2:1 to about 4:1, and the first binder and the second binder are different.
According to a third aspect, there is described an aerosol generating rod comprising an aerosol generating material according to the first aspect or the second aspect.
According to a fourth aspect, there is described an article comprising the aerosol generating material according to the first aspect or the second aspect, or the aerosol generating rod according to the third aspect.
According to a fifth aspect, there is described a delivery system comprising the aerosol generating rod according to the third aspect or the article according to the fourth aspect.

Brief Description of the Drawings

Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings:

Figure 1 is a cross-sectional view of an article comprising an aerosol generating material.
Figure 2 is a cross-sectional view of an aerosol provision device for use with the article of Figure 1.
Figure 3 is a cross-sectional view of the article of Figure 1 being inserted into the aerosol provision device of Figure 2.
Figure 4 is a cross-sectional view of the article of Figure 1 when it is inserted in the aerosol provision device of Figure 2.
Figure 5 is a graph illustrating the amount of formaldehyde measured in the aerosol of several exemplary samples.
Figure 6 is a graph illustrating the amount of acetaldehyde measured in the aerosol of several exemplary samples.

Detailed Description

As used herein, the term "aerosol generating material" describes a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. The aerosol generating material is in an extruded form.
The aerosol generating material may be incorporated into an article for use with a delivery system. An article is sometimes referred to as consumable throughout this disclosure.
As used herein, the term "delivery system" is intended to encompass systems that deliver at least one substance to a user and includes non-combustible aerosol provision systems that release compounds from an aerosol-generating material without combusting the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials.
The article is for use in a non-combustible aerosol provision system. According to the present disclosure, a "non-combustible" aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.
In some embodiments, the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system.
The non-combustible aerosol provision system can be an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement.
The non-combustible aerosol provision system may be an aerosol-generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.
In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product.
Typically, the non-combustible aerosol provision system may comprise a non-combustible aerosol provision device and a consumable for use with the non-combustible aerosol provision device.
In some embodiments, the non-combustible aerosol provision system, such as a non-combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source.
In some embodiments, the non-combustible aerosol provision system comprises an area for receiving the article for use in the non-combustible aerosol-provision system, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent.
In an embodiment, the aerosol generating material is in the form of a rod. The aerosol generating rod may have a total weight of between about 250 mg and about 350 mg. In an embodiment, the aerosol generating rod may be wrapped in a wrapper having a permeability of less than 100 Coresta Units. The aerosol generating rod may have an outer circumference of at least about 19 mm, preferably between about 19 mm and about 23 mm or about 21 mm. This may facilitate insertion of the article into an aerosol generation device.
As used herein, the term "rod" is used to describe a generally cylindrical element of substantially circular, oval, or elliptical cross section.
In some embodiments, the aerosol generating material has a filling value from about 2 cm³/g to about 10 cm³/g. In some embodiments, the aerosol generating material has a filling value of from about 3 cm³/g to about 8 cm³/g, for example the aerosol generating material may have a filling value of from about 4 cm³/g to about 7 cm³/g, such as from about 4 cm³/g to about 6 cm³/g. In some embodiments, the aerosol generating material has a filling value of about 5 cm³/g. When the filling value is between about 2 cm³/g to about 10 cm³/g, for example about 5 cm³/g, a consumable containing the aerosol generating material can achieve the same firmness using less material. Therefore, the overall weight of material used to achieve the same/required filling value, is less, which can provide a saving to the cost of goods.
The aerosol generating material comprises a fibrous material. A fibrous material may be defined as a material which comprises individual fibres which are collectively held together. Fibrous materials also include dietary fibres, i.e. plant-derived materials which cannot be completely broken down by the human digestive enzymes. Fibrous materials can be natural fibres or synthetic fibres. It is understood that the definition of fibrous materials, as used herein, is not intended to be particularly limiting and includes long, thin fibrous materials in addition to more particulate-shaped materials. Examples of fibrous materials can include materials originating from tobacco as well as materials originating from non-tobacco botanical materials.
In some embodiments, the fibrous material comprises a tobacco material. For example, the fibrous material may comprise cut leaf tobacco, whole leaf tobacco, tobacco strips, tobacco stems, tobacco scraps, tobacco fines, and tobacco winnowings.
In some embodiments, the tobacco material is included in an amount of greater than about 60 wt%, based on the total weight of the aerosol generating material. In some embodiments, the tobacco material is included in an amount of greater than about 65 wt%, such as greater than about 70 wt%, such as greater than about 75 wt%, based on the total weight of the aerosol generating material.
In some embodiments, the tobacco material is included in an amount of from about 60 wt% to about 95 wt%, based on the total weight of the aerosol generating material. In some embodiments, the tobacco material is included in an amount of from about 65 wt% to about 90 wt%, such as from about 65 wt% to about 85 wt%, such as from about 70 wt% to about 85 wt%, such as from about 70 wt% to about 80 wt%, based on the total weight of the aerosol generating material.
In some embodiments, the fibrous material comprises a non-tobacco botanical material. Non-tobacco botanical materials may be selected from botanical materials which comprise favourable aroma properties for use in a non-combustible aerosol provision system. For example, the non-tobacco botanical material may comprise relatively few aroma compounds compared to traditional tobacco material; therefore, an aerosol produced from a non-tobacco botanical material may have a different profile of volatile compounds compared to an aerosol produced from a tobacco material. The non-tobacco botanical material may deliver an aerosol which is considered favourable by a consumer of tobacco-based delivery systems. In some embodiments, a non-tobacco botanical material may produce an aerosol, when heated, with a sensorial experience that is comparable to that provided by a conventional combustible product, such as a cigarette. In some embodiments, the non-tobacco botanical material is selected from seed-producing plants which do not develop persistent woody tissue and which are often valued for their medicinal or sensorial characteristics.
For example, the non-tobacco botanical material may be selected from: eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint may be chosen from the following mint varieties: Mentha Arventis, Mentha c.v.,Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v.,Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Memtha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens
In some embodiments, the non-tobacco botanical material may be selected from the list consisting of: oat, wheat, pea, flaxseed, apple, psyllium, ginger, jasmine, cocoa, bamboo, citrus and combinations thereof.
In particular, the non-tobacco botanical material may selected from eucalyptus, star anise, cocoa and hemp, rooibos, mint, fennel, and combinations thereof. For example, the non-tobacco botanical material may be rooibos.
Rooibos, i.e. Aspalathus linearis, is a member of the Fabaceae plant family and is grown in South Africa. Recently, rooibos has been granted a protected designation of origin status which restricts the name, rooibos, to only be used for Aspalathus linearis leaves cultivated in the Cederberg region of South Africa. For the avoidance of doubt, when referring to rooibos herein, it is intended to incorporate any plant material deriving from Aspalathus linearis. It is not intended to only include plant material originating from the Cederberg region of South Africa.
In some embodiments, the aerosol generating material comprises two, or more non-tobacco botanical materials. In some embodiments, the aerosol generating material comprises rooibos and a second non-tobacco botanical material.
As used herein, the term non-tobacco botanical material includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like.
In some embodiments, the non-tobacco botanical material is included in an amount of from about 30 wt% to about 55 wt%, based on the total weight of the aerosol generating material. For example, the non-tobacco botanical material may be included in an amount of from about 35 wt% to about 55 wt%, such as from about 40 wt% to about 55 wt%, such as from about 45 wt% to about 55 wt%, such as from about 50 wt% to about 55 wt%, based on the total weight of the aerosol generating material.
In some embodiments, the non-tobacco botanical material is included in an amount of about 45 wt%, 46 wt%, 47 wt%, 48 wt%, 49 wt%, 50 wt%, 51 wt%, 52 wt%, 53 wt%, 54 wt%, 55 wt%, based on the total weight of the aerosol generating material.
As used herein, the term non-tobacco botanical component includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like.
The non-tobacco botanical component may comprise stem material and leaf material, and for example, the aerosol generating material comprises less than about 10 wt% of stem material, based on the total weight of the aerosol generating material.
It is thought that components within an aerosol generating material may influence the generation of carbonyls. For example, the bulk of the aerosol generating material, i.e. the non-tobacco botanical component in this instance, can impact the generation of carbonyl production. It is thought that carbonyl generation may vary based on the amount of cellulose within the fibrous material, where fibrous materials containing a greater concentration of cellulose generate an aerosol with a higher level of carbonyls. It is also thought that hemicellulose content and the natural sugars contained within a material impact the generation of carbonyl compounds. For example, materials which have a relatively greater amount of hemicellulose, and/or sugar, may generate aerosols with a higher concentration of carbonyls.
Certain parts of a plant may contain more, or less, cellulose material, compared to other parts of the plant. For instance, the stem of a non-tobacco botanical plant may contain a higher concentration of cellulose material compared to other parts of the non-tobacco plant, such as the leaves. By reducing the amount of material containing a high concentration of cellulose, one may be able to minimise the exposure of the consumer to an increase level of carbonyls. For example, by reducing the amount of stem material utilised in an aerosol generating material, one may be able to minimise the exposure of the consumer to an increased level of carbonyls.
The different parts of a non-tobacco botanical plant material may be separated by any known method. For example, the different parts may be separated by visual inspection. The different parts may be separated by threshing. The different parts may be separated based on density of the material. The different parts may be separated based on particle size.
In some embodiments, the non-tobacco botanical component comprises bark material and the aerosol generating material comprises less than about 10 wt% bark, based on the total weight of the aerosol generating material.
In some embodiments, the non-tobacco botanical component comprises leaves comprising a midrib and veins and the aerosol generating material comprises less than about 10 wt% midrib and/or veins, based on the total weight of the aerosol generating material.
In an example, an aerosol generating material comprises a non-tobacco botanical component, the non-tobacco botanical component comprising a root material and a leaf material; and an active and/or a flavourant; wherein the aerosol generating material comprises less than about 10 wt% of root material, based on the total weight of the aerosol generating material.
In an example, an aerosol generating material comprises a non-tobacco botanical component, the non-tobacco botanical component comprising a bark material and a leaf material; and an active and/or a flavourant; wherein the aerosol generating material comprises less than about 10 wt% of bark material, based on the total weight of the aerosol generating material.
In an example, an aerosol generating material comprises a non-tobacco botanical component, the non-tobacco botanical component comprising a husk material and a leaf material; and an active and/or a flavourant; wherein the aerosol generating material comprises less than about 10 wt% of husk material, based on the total weight of the aerosol generating material.
In an example, an aerosol generating material comprises a non-tobacco botanical component, the non-tobacco botanical component comprising a shell material and a leaf material; and an active and/or a flavourant; wherein the aerosol generating material comprises less than about 10 wt% of shell material, based on the total weight of the aerosol generating material.
In some embodiments, the non-tobacco botanical component may be in the form of particles. For example, the non-tobacco botanical component may be in the form of ground particles. The component may be ground into a suitable particle size by any method known by the skilled person.
The non-tobacco botanical material may have an average particle size, such as a D50, of less than 200 µm, such as less than 150 µm, such as less than 125 µm, such as less than 100 µm, such as less than 90 µm, such as less than 80 µm, such as less than 70 µm.
The non-tobacco botanical material may have an average particle size, such as a D90 of less than 200 µm, such as less than 150 µm, such as less than 125 µm, such as less than 100 µm, such as less than 90 µm, such as less than 80 µm, such as less than 70 µm.
In some embodiments, the non-tobacco material has a particle size, such as a D90 of less than about 60 µm. In some embodiments, the non-tobacco material has a particle size, such as a D90 of less than about 70 µm. In some embodiments, the non-tobacco material has a particle size, such as a D90 of less than about 80 µm. In some embodiments, the non-tobacco material has a particle size, such as a D90 of less than about 90 µm. In some embodiments, the non-tobacco material has a particle size, such as a D90 of less than about 100 µm.
In some embodiments, the non-tobacco material has a particle size, such as a D90 of about 60 µm. In some embodiments, the non-tobacco material has a particle size, such as a D90 of about 70 µm. In some embodiments, the non-tobacco material has a particle size, such as a D90 of about 80 µm. In some embodiments, the non-tobacco material has a particle size, such as a D90 of about 90 µm. In some embodiments, the non-tobacco material has a particle size, such as a D90 of about 100 µm.
In some embodiments, the maximum dimension of the non-tobacco botanical material can be up to about 1 mm, up to about 1.25 mm, up to about 1.5 mm.
The particle size of the non-tobacco botanical material can influence the roughness of the sheet or shredded sheet of aerosol generating material.
The particle size of the non-tobacco botanical material may be modified by any process known to a person skilled in the art. For example, the material may be ground in order to reduce the particle size. It is thought that reducing the moisture content of the non-tobacco material may facilitate more efficient particle size reduction by grinding. For example, the non-tobacco botanical material may be dried, such as in an oven, prior to grinding. In some instances, it is preferable to reduce the moisture content of the non-tobacco botanical material by up to about 5% prior to grinding.
The aerosol generating material comprises one or more additives for scavenging carbonyls. As used herein, the term carbonyls is intended to encompass reactive carbonyl species which may be found in an aerosol generated from an aerosol generating material. Reactive carbonyl species include aldehydes and ketones such as formaldehyde, acetaldehyde, 2,3-butanedione, 2,3-pentanedione, acetoin, acetone, acrolein, butyraldehyde, crotonaldehyde, glyoxal, isobutyraldehyde, methyl ethyl ketone, methylglyoxal, and propionaldehyde.
It is noted that different aerosol generating materials may produce differing levels of carbonyls when heated, for example in an aerosol provision system.
It is thought that the components within the aerosol generating material may influence the generation of carbonyls. For example, the bulk of the aerosol generating material, i.e. the fibrous material in this instance, can impact the generation of carbonyl production. It is thought that carbonyl generation may vary based on the amount of cellulose within the fibrous material, where fibrous materials containing more cellulose generate an aerosol with a higher level of carbonyls.
It is also thought that carbonyl generation may be influenced by temperature, specifically the temperature to which the aerosol generating material is heated. Many aerosol provision systems are configured to heat an aerosol generating material to approximately 250-300 °C. However, such systems typically take 15-20+ seconds in order to reach optimum temperature. This initial heating profile may be referred to as the ramp up time and illustrates the amount of time that a user must wait before taking their first puff. There may be a desire to decrease this ramp up time, for example to less than 10 seconds, perhaps less than 5 seconds. This would be advantageous because the user has less time to wait before their first puff of a session. However, in order to achieve such a fast ramp up time, it will likely be necessary for the aerosol provision system to reach higher temperatures, such as about 500 °C, about 600 °C, or even above 600 °C. It is hypothesised that when exposed to higher temperatures, aerosol generating materials will produce higher levels of carbonyls.
Thus, the inclusion of an additive for scavenging carbonyls would facilitate the use of a variety of fibrous materials and also allow heating of an aerosol generating material to a higher temperature, while minimising the exposure of the consumer to an increased level of carbonyls.
In some embodiments, the additive is selected from the list consisting of: ammonium-based scavengers, anti-oxidant-based scavengers, organic acid-based scavengers, polyphenol-based scavengers, flavonoid and (ester) derivative -based scavengers, amine-based scavengers, phenolic-based scavengers, amino acid-based scavengers and combinations/mixtures thereof.
Ammonium-based scavengers may be selected from: diammonium phosphate, ammonium dihydrogen phosphate, ammonium magnesium phosphate, and combinations/mixtures thereof.
Polyphenol-based scavengers may be selected from: chlorogenic acid, gallic acid, and combinations/mixtures thereof.
An example of an antioxidant-based scavenger is ferulic acid.
An example of an organic acid-based scavenger is fumaric acid.
Flavonoid and (ester) derivative -based scavengers may be selected from: (+)-catechin hydrate, (-)-epicatechin, (-)-epigallocatechin gallate, and combinations/mixtures thereof.
Examples of phenolic-based scavengers include: hydroxytyrosol, and phloroglucinol dihydrate, and combinations thereof.
Amine-based scavengers may be selected from: ethylenediamine hydrochloride, polyallylamine hydrochloride, ethylenediamine diacetate, 4-aminobenzoic acid, 3-aminobenzoic acid, and combinations/mixtures thereof.
Amino acid-based scavengers may be selected from: lysine, arginine, proline, methionine, L-cystine, and combinations thereof.
In some embodiments, the additive is selected from sugar alcohols such as: ethylene glycol, glycerol, erythritol, threitol, arabitol, xylitol, ribitol, mannitol, sorbitol, galactitol, fucitol, iditol, inositol, volemitol, isomalt, maltitol, lactitol, maltotriitol, maltotetraitol, polyglycitol, and combinations/mixtures thereof.
In some embodiments, the additive is selected from diammonium phosphate, gallic acid, fumaric acid, chlorogenic acid, and ferulic acid. In some embodiments, the additive is diammonium phosphate.
In some embodiments, the additive is included in an amount of from about 0.01 wt% to about 5 wt%, based on the total weight of the aerosol generating material. For example, the additive may be included in an amount of from about 0.1 wt% to about 5 wt%, from about 0.2 wt% to about 5 wt% from about 0.5 wt% to about 5 wt%, from about 0.5 wt% to about 4.5 wt%, from about 0.5 wt% to about 4 wt%, from about 0.5 wt% to about 3.5 wt%, from about 0.5 wt% to about 3 wt%, from about 0.5 wt% to about 2.5 wt%, from about 0.5 wt% to about 2 wt%, based on the total weight of the aerosol generating material.
In some embodiments, the additive is included in an amount of about 0.5 wt%, based on the total weight of the aerosol generating material. In some embodiments, the additive is included in an amount of about 1 wt%, based on the total weight of the aerosol generating material. In some embodiments, the additive is included in an amount of about 2 wt%, based on the total weight of the aerosol generating material. In some embodiments, the additive is included in an amount of about 3 wt%, based on the total weight of the aerosol generating material. In some embodiments, the additive is included in an amount of about 4 wt%, based on the total weight of the aerosol generating material. In some embodiments, the additive is included in an amount of about 5 wt%, based on the total weight of the aerosol generating material.
In some embodiments, the aerosol generating material comprises two additives, and the combined total inclusion amount of both additives is from about 0.01 wt% to about 5 wt%, based on the total weight of the aerosol generating material. For example, the additive may be included in an amount of from about 0.1 wt% to about 5 wt%, from about 0.2 wt% to about 5 wt% from about 0.5 wt% to about 5 wt%, from about 0.5 wt% to about 4.5 wt%, from about 0.5 wt% to about 4 wt%, from about 0.5 wt% to about 3.5 wt%, from about 0.5 wt% to about 3 wt%, from about 0.5 wt% to about 2.5 wt%, from about 0.5 wt% to about 2 wt%, based on the total weight of the aerosol generating material.
In some embodiments, the aerosol generating material comprises two additives, and the combined total inclusion amount of both additives is about 0.5 wt%, based on the total weight of the aerosol generating material. In some embodiments, the combined total inclusion of both additives is about 1 wt%, based on the total weight of the aerosol generating material. In some embodiments, the combined total inclusion of both additives is about 2 wt%, based on the total weight of the aerosol generating material. In some embodiments, the combined total inclusion of both additives is about 3 wt%, based on the total weight of the aerosol generating material. In some embodiments, the combined total inclusion of both additives is about 4 wt%, based on the total weight of the aerosol generating material. In some embodiments, the combined total inclusion of both additives is about 5 wt%, based on the total weight of the aerosol generating material.
In some embodiments, the aerosol generating material comprises three additives. In some embodiments, the aerosol generating material comprises four, or more, additives.
In some embodiments, the aerosol generating material comprises a combination of diammonium phosphate and gallic acid. In some embodiments, the aerosol generating material comprises a combination of diammonium phosphate and fumaric acid. In some embodiments, the aerosol generating material comprises a combination of diammonium phosphate and chlorogenic acid. In some embodiments, the aerosol generating material comprises a combination of diammonium phosphate and ferulic acid. In some embodiments, the aerosol generating material comprises a combination of diammonium phosphate and ethylenediamine diacetate.
In some embodiments, the aerosol generating material comprises a combination of diammonium phosphate, gallic acid, and fumaric acid. In some embodiments, the aerosol generating material comprises a combination of diammonium phosphate, gallic acid, and chlorogenic acid. In some embodiments, the aerosol generating material comprises a combination of diammonium phosphate, gallic acid, and ferulic acid. In some embodiments, the aerosol generating material comprises a combination of diammonium phosphate, fumaric acid, and chlorogenic acid. In some embodiments, the aerosol generating material comprises a combination of diammonium phosphate, ferulic acid, and chlorogenic acid. In some embodiments, the aerosol generating material comprises a combination of diammonium phosphate, ferulic acid, and fumaric acid. In some embodiments, the aerosol generating material comprises a combination of diammonium phosphate, ethylenediamine diacetate, and fumaric acid.
The aerosol generating material comprises an active and/or a flavourant.
An active as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropics, psychoactives. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical.
The active substance may be a legally permissible recreational drug.
The active substance may comprise nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12.
The active substance may comprise one or more constituents, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.
The active substance may be CBD or a derivative thereof.
The active may be derived from one of more botanicals, such as one or more of the botanicals described hereinabove. The active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof.
The aerosol-generating material may not comprise tobacco and/or may not comprise tobacco-derived material. In some embodiments, the aerosol-generating material is substantially free from tobacco or tobacco derived material.
As used herein, the terms "flavour" and "flavourant" refer to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas.
In some embodiments, the flavour comprises menthol, spearmint and/or peppermint. In some embodiments, the flavour comprises flavour components of cucumber, blueberry, citrus fruits and/or redberry. In some embodiments, the flavour comprises eugenol. In some embodiments, the flavour comprises flavour components extracted from tobacco. In some embodiments, the flavour comprises flavour components extracted from cannabis.
In some embodiments, the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. 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, WS-3 or WS-23.
The flavour may be in the form of a flavour composition which comprises or consists of the flavour. The flavour composition may comprise the flavour and one or more other components, such as a flavour, or a solvent, such as water, ethanol, isopropanol, n-butanol, ethyl acetate, isopropyl acetate, butyl acetate, anisole, glycerol or propylene glycol. The inclusion of a solvent in the flavour composition may improve the homogeneity of the flavour in the aerosol-generating material and improve the absorption or adsorption of the flavour into the aerosol-generating material.
In some embodiments, the active and/or flavourant is included in an amount of from about 0.5 wt% to about 10 wt%, based on the total weight of the aerosol generating material. For example, the active and/or flavourant may be included in an amount of from about 1 wt% to about 10 wt%, from about 1.5 wt% to about 10 wt%, from from about 1.5 wt% to about 9 wt%, from about 1.5 wt% to about 8 wt%, from about 1.5 wt% to about 7 wt%, from about 1.5 wt% to about 6 wt%, from about 1.5 wt% to about 5 wt%, from about 1.5 wt% to about 4 wt%, based on the total weight of the aerosol generating material.
In some embodiments, the aerosol generating material comprises an acid. For example, the acid may be selected from the list consisting of: levulinic acid, lactic acid, benzoic acid, citric acid, 2-methylbutyric acid, 2-methylvaleric acid, and combinations thereof. In some embodiments, the acid is benzoic acid. In some embodiments, the acid is levulinic acid. In some embodiments, the acid is a combination of levulinic acid and benzoic acid.
The total amount of the acid may be from about 0.1% to about 5% by weight of the aerosol generating material. For example, the total amount of the acid is from about 0.1% to about 5%, from about 0.5% to about 5%, from about 1% to about 5%, from about 1.5% to about 5%, from about 2% to about 5%, or from about 2.5% to about 5% by weight of the aerosol generating material.
In some embodiments, the aerosol generating material may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and/or filler may also be present. Optionally, a solvent, such as water, is also present and one or more other components of the aerosol-generating material may or may not be soluble in the solvent.
The binder may be selected from one or more compounds selected from the group comprising alginates, pectins, starches (and derivatives), amylose, amylopectin, celluloses (and derivatives), gums, silica or silicones compounds, clays, polyvinyl alcohol, a polysaccharide such as galactomannan or glucomannan, a gum such as acacia gum, xanthan gum, pullulan, gellan gum, tragacanth gum, gum karaya, and combinations thereof. The binder may be selected from the list consisting of: modified starch, glucomannan, curdlan gum, amylopectin, HPMC, maltodextrin, carrageenan, xanthan gum, alginate, gum arabic, karaya gum, locust bean gum, gellan gum, agar, CMC, and combinations thereof.
In some embodiments, the aerosol generating material comprises a mixture of at least two binders. In some embodiments, when the aerosol generating material comprises at least two binders, the two binders are different. In some embodiments, the aerosol generating material comprises at least three binders. In some embodiments, each of the three binders are different. In some embodiments, the aerosol generating material comprises modified starch, glucomannan, and curdlan gum.
In some embodiments, the total binder content, is from about 10 wt% to about 20 wt%, based on the total weight of the aerosol generating material. For example, the total binder content may be from about 10 wt% to about 18 wt%, from about 12 wt% to about 18 wt%, from about 12 wt% to about 16 wt%, from about 14 wt% to about 16 wt%, based on the total weight of the aerosol generating material.
In some embodiments, when the aerosol generating material comprises a first and second binder, which are different, the binders may collectively be called a binder system. In some embodiments, a ratio of the fibrous material to the binder system is from about 2:1 to about 4:1. For example, a ratio of the fibrous material to the binder system is from about 2:1 to about 7:2, from about 5:2 to about 7:2, from about 3:1 to about 7:2. In some embodiments, a ratio of the fibrous material to the binder system is about 3:1. In some embodiments, a ratio of the non-tobacco botanical material to the binder system is from about 2:1 to about 4:1, such as from about 2:1 to about 7:2, from about 5:2 to about 7:2, from about 3:1 to about 7:2. In some embodiments, a ratio of the non-tobacco botanical material to the binder system is about 3:1.
Where present, the filler may include one or more organic fillers, such as wood pulp, cellulose, cellulose derivatives (e.g. microcrystalline cellulose and methylcellulose) and a metal carbonate, such as calcium carbonate. In some embodiments, the aerosol generating material contains calcium carbonate, such as chalk. In some embodiments, the aerosol generating material does not contain calcium carbonate.
In some embodiments, the filler is included in an amount of less than about 10 wt% based on the total weight of the aerosol generating material. For example, the filler may be included in an amount of less than about 9 wt%, such as less than about 8 wt%, less than about 7 wt%, less than about 6 wt%, less than about 5 wt%, less than about 4 wt%, less than about 3 wt%, based on the total weight of the aerosol generating material.
In some embodiments, the aerosol generating material comprises an aerosol-former material. An aerosol-former material is a material that is capable of forming an aerosol. In some embodiments, the aerosol-former material may comprise one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.
In some embodiments, the amount of aerosol former material incorporated into the aerosol-generating material may be at least about 3 wt%, at least about 4 wt%, 5 wt%, 6 wt%, 7 wt%, 8 wt%, 9 wt%, 10 wt%, 11 wt%, 12 wt%, 13 wt%, 14 wt%, 15 wt%, 16 wt%, 17 wt%, 18 wt%, 19 wt%, or at least about 20 wt% based on the total weight of the aerosol generating material. In some embodiments, the amount of aerosol former material incorporated into the pre-cursor material and/or aerosol-generating material may be up to about 15 wt%, up to about 16 wt%, 17 wt%, 18 wt%, 19 wt%, 20 wt%, 21 wt%, 22 wt%, 23 wt%, 24 wt%, 25 wt%, 26 wt%, 27 wt%, 28 wt%, 29 wt% or up to about 30 wt% based on the total weight of the aerosol generating material.
In some embodiments, aerosol former material is included in an amount of from about 3% to about 30% by weight of the aerosol generating material, such as in an amount of from about 10% to about 30%.
The aerosol generating material may comprise one or more other materials. For example, the aerosol-generating material may comprise one or more of pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.
As used herein, the term sugar is intended to include simple sugars such as monosaccharides and compound sugars such as disaccharides. When referring to monosaccharides and/or disaccharides herein, the intention is to refer to purposely added monosaccharides and/or disaccharides. It is appreciated that there may be a certain level of monosaccharides and/or disaccharides naturally present in, e.g. non-tobacco botanical materials, however, when referring to these components herein, the intention is to any additional inclusion.
In some embodiments, the aerosol generating material may comprise a monosaccharide and/or a disaccharide. For example, the aerosol generating material may comprise glucose, fructose, galactose, sucrose, lactose, maltose, and combinations/mixtures thereof. Including a sugar, such as a monosaccharide and/or a disaccharide may facilitate the production of an extruded aerosol generating material exhibiting preferable characteristics. It is thought that, when preparing an extruded material, the level of sugar present in the mixture plays an important role in the resulting extruded material. For example, extruded materials which contain too little sugar, or too much sugar, may not form extruded structures which are suitable for further use in a consumable. The use of such extruded materials would be particularly limited.
Materials, such as certain non-tobacco botanical materials, may contain less sugar than tobacco material and therefore additional sugar may be incorporated in extruded aerosol generating materials comprising such non-tobacco botanical materials.
In some embodiments, the aerosol generating material does not include monosaccharides and/or disaccharides. However, in order to produce suitable aerosol generating materials without the use of monosaccharides and/or disaccharides, alternative additional components may be required, for example aerosol formers such as propylene glycol and/or glycerol may be added in order to facilitate production of a suitable extruded material. Alternatively, and/or additionally, one or more binders may be incorporated into the mixture before extruding, as discussed elsewhere herein.
In some embodiments, the aerosol generating material comprises a monosaccharide and/or a disaccharide in an amount of from about 0.5 wt% to about 15 wt%, based on the total weight of the aerosol generating material. For example, the aerosol generating material may comprise a monosaccharide and/or a disaccharide in an amount of from about 0.5 wt% to about 10 wt%, from about 0.5 wt% to about 8 wt%, from about 0.5 wt% to about 7 wt%, from about 0.5 wt% to about 6 wt%, from about 0.5 wt% to about 5 wt%, from about 0.5 wt% to about 4 wt%, from about 0.5 wt% to about 3 wt%, based on the total weight of the aerosol generating material.
In some embodiments, the monosaccharide and/or disaccharide is included in an amount of up to about 3 wt%, based on the total weight of the aerosol generating material, such as up to about 4 wt%, up to about 5 wt%, up to about 6 wt%, up to about 7 wt%, up to about 8 wt%, up to about 9 wt%, up to about 10 wt%, based on the total weight of the aerosol generating material.
In some embodiments, the extruded aerosol generating material comprises substantially no monosaccharides and/or disaccharides. In particular, the extruded aerosol generating material may comprise no additional monosaccharides and/or disaccharides other than those that may naturally be present in the non-tobacco botanical material.
The aerosol generating material is in extruded form. An extruded material is a material which is prepared by mixing components to form a mixture and extruding the mixture using an extruder equipped with an orifice, such as a shaping die.
Extrusion may be performed using one of the main classes of extruders: screw, twin screw, sieve and basket, roll, and ram extruders.
During extrusion the mixture may be exposed to elevated pressure when forced though the orifice to form an extruded material. In some embodiments, the extruded material has an elongated form and/or it may be cut into segments of a desired length as it exits the extruder. A rod-like extruded material may subsequently be cut into segments of desired length.
The extruded material may be shaped by the orifice or die through which it is forced. In some embodiments, the extruded material is cut into pieces of desired length. The pieces formed in this way may be used as aerosol generating components or they may undergo further processing. The orifice or die may be shaped to provide a strand of extruded pre-cursor material. For example, the extruded pre-cursor material may have the form of a cylindrical rod. Alternatively, the extruded pre-cursor material may have different cross-sectional shapes, including oval, polygonal (such as triangular, square, etc.), and stars.
The extruder may be operated without applying heat to the system (for example, at room/ambient temperature) or at an elevated temperature. Where the extruder is operated at an elevated temperature, the extruder may be operated at a temperatures of up to about 200 °C. After the material exits the die of the extruder, it may be cooled, for example to room temperature, to provide the extruded material.
The mixture may be exposed to pressures ranging from about 2 bar to about 100 bar, or from about 5 bar to about 60 bar, depending on the design of the die being used.
Flavour may be applied to the extruded material. The flavour may be applied by applying a film of the flavour composition onto a surface of the material, spraying the flavour composition onto the material, applying droplets of the flavour composition onto a surface of the material or submerging the material in a solution comprising the flavour composition.
Liquids may be added to the mixture during the extrusion process. For example, water may be added to the mixture, for example as a processing aid to assist dissolution or solubilisation of components of the mixture, or to aid binding or agglomeration. Alternatively, or additionally, a wetting agent may be added to the mixture.
The liquid may be an aerosol former material such as glycerol or others discussed herein, such as water. When liquid is added to the mixture in this manner, the liquid is applied not only on the surface, but, as a result of the extruder pressure combined with the intensive mixing by high shear forces, the extruded pre-cursor material becomes impregnated with the liquid. Where the liquid is an aerosol former material, this can result in a high availability of the aerosol former material in the extruded pre-cursor material to enhance evaporation of flavour components and other components of the final aerosol-forming material. Where the liquid is water, this may assist in the extrusion process, allowing a suitable/useable extruded aerosol generating material to be formed.
In some embodiments, the moisture content of the mixture is from about 5 wt% to about 15 wt%, such as from about 7 wt% to about 13 wt%, such as from about 10 wt% to about 12 wt%, based on the total weight of the mixture.
In some embodiments, the extruded material is formed into a desired shape selected to enhance or promote the release of active and/or flavour, for example by providing a form having a large surface area per unit volume. This large surface area may be provided on the outer surface of the extruded pre-cursor material, for example by selecting cross-sectional shapes with large perimeter.
The orifice or die may be shaped to provide an extruded material with inner channels. The presence of such inner channels provide further surface area and can enhance active and/or flavour release. The channel structure of the extruded aerosol generating material has enlarged inner surface area leading to improved heat and mass transfer. As a result, such components exhibit better, more uniform aerosol delivery. Furthermore, the structure with channels exhibits significantly improved strength in both the radial and axial directions, which is beneficial for the further processing of the aerosol generating material, for example when it is cut into segments and incorporated into a consumable.
Figure 1 is a cross-sectional view of an article 9 for use in an aerosol delivery system.
The article 9 comprises a mouthpiece 10, and an aerosol generating section 11, connected to the mouthpiece 10. In the present example, the aerosol generating section 11 comprises a body of aerosol generating material 2 in the form of an extruded rod. The article 9 comprises a downstream end 2b and an upstream end 2a distal from the downstream end 2b. The article 9 comprises a longitudinal axis X-X'. The aerosol-generating section comprises aerosol-generating material in the form of an extruded body 1 comprising channels 4a, 4b and a cavity 3a for receiving an aerosol generator.
The mouthpiece 10 includes a cooling section 12, also referred to as a cooling element, positioned immediately downstream of and adjacent to the aerosol-generating section 11. The cooling section 12 is in an abutting relationship with the aerosol-generating material 2. The mouthpiece 2 also includes, in the present example, a body of material 13 downstream of the cooling section 12, and a hollow tubular element 14 downstream of the body of material 13, at the mouth end of the article 9. The cooling section 12 provides a physical displacement between the aerosol-generating section 11 and the body of material 13. The physical displacement provided by the cooling section 12 can provide a thermal gradient across the length of the cooling section 12.
A tipping paper (not shown) is wrapped around the full length of the mouthpiece 10 and over part of the aerosol-generating section 11 and has an adhesive on its inner surface to connect the mouthpiece 10 and aerosol-generating section 11. In the present example, the aerosol-generating section 11 comprises a wrapper (not shown), which forms a first wrapping material, and the tipping paper forms an outer wrapping material which extends at least partially over the body of aerosol-generating material 2 to connect the mouthpiece 10 and aerosol-generating material 2. In some examples, the tipping paper can extend only partially over the rod of aerosol-generating material.
A moisture impermeable wrapper (not shown) circumscribes aerosol-generating material 2 and comprises a paper wrapper. In other embodiments, the wrapper comprises a aluminium foil, optionally comprising a barrier coating to make the material of the wrapper substantially moisture impermeable.
The body of material 13 and hollow tubular element 14 each define a substantially cylindrical overall outer shape and share a common longitudinal axis. The body of material 13 is wrapped in a first plug wrap (not shown). Preferably, the first plug wrap has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 40 gsm. Preferably, the first plug wrap has a thickness of between 30 µm and 60 µm, more preferably between 35 µm and 45 µm. Preferably, the first plug wrap is a nonporous plug wrap, for instance having a permeability of less than 100 Coresta units, for instance less than 50 Coresta units. However, in other embodiments, the first plug wrap can be a porous plug wrap, for instance having a permeability of greater than 200 Coresta Units.
In the present example, the body of material 13 is formed from filamentary tow. In the present example, the tow used in the body of material 13 has a denier per filament (d.p.f.) of 8.4 and a total denier of 21,000. Alternatively, the tow can, for instance, have a denier per filament (d.p.f.) of 9.5 and a total denier of 12,000. In the present example, the tow comprises plasticised cellulose acetate tow. The plasticiser used in the tow comprises about 7% by weight of the tow. In the present example, the plasticiser is triacetin. In other examples, different materials can be used to form the body of material 13. For instance, rather than tow, the body 13 can be formed from paper, for instance in a similar way to paper filters known for use in cigarettes.
The article may have a ventilation level of about 10% of the aerosol drawn through the article. In alternative embodiments, the article can have a ventilation level of between 1% and 20% of aerosol drawn through the article, for instance between 1% and 12%. Ventilation at these levels helps to increase the consistency of the aerosol inhaled by the user at the mouth end 2b, while assisting the aerosol cooling process. The ventilation is provided directly into the mouthpiece 10 of the article 9. In the present example, the ventilation is provided into the cooling section 12, which has been found to be particularly beneficial in assisting with the aerosol generation process. The ventilation is provided via perforations, in the present case formed as a single row of laser perforations, positioned 13 mm from the downstream, mouth-end 2b of the mouthpiece 10. In alternative embodiments, two or more rows of ventilation perforations may be provided. These perforations pass though the tipping paper, second plug wrap and cooling section 12. In alternative embodiments, the ventilation can be provided into the mouthpiece at other locations, for instance into the body of material 13 or tubular element 14. Preferably, the article is configured such that the perforations are provided about 28mm or less from the upstream end of the article 9, preferably between 20mm and 28mm from the upstream end of the article 9. In the present example, the apertures are provided about 25mm from the upstream end of the article.
The body 2 has a cross sectional shape that is substantially the same as the cross sectional shape of the mouthpiece 10. The body 2 has a diameter that is substantially the same as a diameter of the mouthpiece 10.
The body 2 may have a pressure drop of from about 0.001 mmWg/mm to about 70 mmWg/mm or from about 1 to about 40 mmWg/mm. In the present embodiment, the body 2 has a pressure drop of up to 20 mmWg/mm.
The aerosol-generating material and articles disclosed herein may be for use in a non-combustible aerosol provision device comprising an aerosol generator for insertion into the aerosol-generating material.
As shown Figure 2, the components of an exemplary non-combustible aerosol provision device 15 are shown in a simplified manner. Particularly, the elements of the non-combustible aerosol provision 15 are not drawn to scale in Figure 2. Elements that are not relevant for the understanding of this embodiment have been omitted to simplify Figure 2.
The non-combustible aerosol provision device 15 comprises a housing 16 comprising an area 17 for receiving an article. The area is in the form of a cavity, open at the proximal end (or mouth end) for receiving an aerosol-generating article. The distal end of the cavity is spanned by an aerosol-generating assembly comprising an aerosol generator 18. In this embodiment, the aerosol-generator is in the form of a resistively-heated elongate pin.
The aerosol generator 18 is retained by a heater mount (not shown) such that an active heating area of the aerosol generator is located within the cavity. The active heating area of the aerosol generator 18 is positioned within the aerosol-generating section of an aerosol-generating article when the aerosol-generating article is fully received within the cavity.
The aerosol generator 18 is configured for insertion into the aerosol-generating section of an aerosol-generating article. As noted above, the aerosol generator 18 is shaped in the form of a pin terminating in a rounded point. The pin has a length dimension that is greater than its width dimension.
Referring to Figure 3, in a pre-operational state, an article 9 for use with the non-combustible aerosol provision device 15 is provided. As previously described, the article 9 comprises an upstream end 2a adjacent to an aerosol-generating section 11. The article 9 also comprises a downstream end 2b distal from the aerosol-generating section 11 and adjacent mouthpiece 10. The aerosol-generating section 11 is configured to receive the aerosol generator 18 by moving the article 9 towards the aerosol-generator 18 of the device 15 and into the area 17. The aerosol generator 18 is received in the cavity 3a of the article 9.
Referring now to Figure 4, when the article 9 is received into the area 17, the wall of the cavity 3a comes into thermal proximity with the aerosol generator 803. When the article 9 is fully received in the area 17, the wall of the cavity 3a may be in direct contact with the aerosol generator 18.
When the aerosol-generator 18 is actuated it heats up and the body of aerosol-generating material 2 is warmed and volatile substances are generated or evolved. As a user draws on the mouthpiece 10, air is drawn into the article 9 and the volatile substances condense to form an inhalable aerosol. This aerosol passes through the mouthpiece 10 of the article 9 and into the user's mouth.

Experimental

Extruded rods were manufactured having the formulations set out in Table 1 and samples were prepared according to Table 2, where the added compounds were dissolved in 25 µl of water and injected into the aerosol generating material.

Table 1

Rod A		Rod B
Tobacco	70%	Rooibos	53.6%
Glucomannan	5%	Modified Starch	6%
Amylopectin	3%	Glucomannan	5%
MCC	4%	Curdlan Gum	3%
PG	2%	Glucose	3%
VG	16%	Nicotine mix*	18.9%
		CaCO₃	4%
		Propylene Glycol	2%
		Glycerol	4.5%

*Nicotine mix = glycerol (68.7%), nicotine (12.1%), levulinic acid (1.9%), benzoic acid (7.3%), and water (10.0%).

Table 2

Sample Name	Compound Added	Inclusion Amount
Control A (Rod A)	N/A	N/A
Control B (Rod B)	N/A	N/A
Sample A	DAP	1%
Sample B	DAP	0.5%

Sample A is based on Rod A and Control A which all contain tobacco material. Sample B is based on Rod B and Control B which all contain rooibos material.
The samples were conditioned in ISO conditions (22±2°C/60±5% RH) in unsealed aluminium foil bags for a minimum of 48 hours and no more than 240 hours (10 days).
The conditioned samples were smoked following the Canadian Extreme ("Intense") Conditions: 55±0.5 mL puff volume, 2.0±0.1 sec duration, and 30±1 sec interval, bell shaped puff profile, 0% vent blocking, 10 puffs per consumable. The consumables were smoked using a heated product device configured to initially rapidly heat the consumable to a temperature greater than 500 °C.
Compounds of interest contained in the aerosol were trapped using a conditioned glass fibre filter disc (pad) and a cryogenic trap (impinger) containing acetonitrile. The pad was combined with the impinger solution and extracted using a platform shaker. An aliquot of the extract was mixed with Type 1 water and combined with internal standard solution (acetaldehyde-d₄, acetone-d₆, methyl ethyl ketone-ds, 2,3-butanedione-ds, and 2,3-pentanedione-d₅, as required) followed by derivatisation using an o-(2,3,4,5,6-pentafluorobenzyl)hydroxylamine hydrochloride (PFBHA) solution. After derivatisation, the sample was acidified and extracted with toluene. The toluene extract was analysed by GC-MS under selective ion monitoring (SIM) mode using a diphenyl dimethyl polysiloxane capillary column or equivalent.
The amount of formaldehyde and acetaldehyde from five replicates was measured, averaged, and is illustrated in Fig. 5 and Fig. 6 respectively. It is clear that both diammonium phosphate were effective in reducing the amount of formaldehyde and acetaldehyde present in the aerosol compared to the control sample containing no additive for scavenging carbonyls.
The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc, other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.

Clauses

The following clauses are not intended to be interpreted as claims but are recited for exemplary purposes only.

1. An extruded aerosol generating material comprising:
- a fibrous material,
- an active and/or a flavourant, and
- an additive for scavenging carbonyls.
2. The extruded aerosol generating material according to clause 1, wherein the fibrous material is a tobacco material.
3. The extruded aerosol generating material according to clause 2, wherein the tobacco material is included in an amount of greater than about 60 wt% based on the total weight of the extruded aerosol generating material.
4. The extruded aerosol generating material according to clause 2 or clause 3, wherein the tobacco material is included in an amount of from about 60 wt% to about 90 wt%, optionally from about 65 wt% to about 85 wt%, about 70 wt% to about 80 wt%, based on the total weight of the extruded aerosol generating material.
5. The extruded aerosol generating material according to clause 1, wherein the fibrous material is a non-tobacco botanical material.
6. The extruded aerosol generating material according to clause 5, wherein the non-tobacco botanical material is selected from the list consisting of: eucalyptus, star anise, cocoa, hemp, rooibos, mint, fennel, and combinations thereof.
7. The extruded aerosol generating material according to clause 5 or clause 6, wherein the non-tobacco botanical material is rooibos.
8. The extruded aerosol generating material according to any one of clauses 5 to 7, wherein the non-tobacco botanical material is present in an amount of from about 30 wt% to about 55 wt%, based on the total weight of the extruded aerosol generating material.
9. The extruded aerosol generating material according to any one of clauses 1 to 8, further comprising additive for scavenging carbonyls, wherein the additive is selected from the list consisting of: ammonium-based scavengers; polyphenol-based scavengers; anti-oxidant-based scavengers; organic acid-based scavengers; flavonoid and (ester) derivative-based scavengers; phenolic-based scavengers; amine-based scavengers; amino acid-based scavengers, and combinations thereof.
10. The extruded aerosol generating material according to clause 9, wherein the ammonium-based scavengers are selected from: diammonium phosphate, ammonium dihydrogen phosphate, ammonium magnesium phosphate, and combinations thereof.
11. The extruded aerosol generating material according to clause 9, wherein the polyphenol-based scavengers are selected from: chlorogenic acid and gallic acid.
12. The aerosol generating material according to clause 9, wherein the anti-oxidant-based scavenger is ferulic acid.
13. The aerosol generating material according to clause 9, wherein the organic acid-based scavenger is fumaric acid.
14. The extruded aerosol generating material according to clause 9, wherein the flavonoid and (ester)derivative-based scavengers are selected from: (+)-catechin hydrate, (-)-epicatechin, (-)-epigallocatechin gallate, and combinations thereof.
15. The aerosol generating material according to clause 9, wherein the phenolic-based scavengers are selected from: hydroxytyrosol, phloroglucinol dihydrate, and combinations thereof.
16. The extruded aerosol generating material according to clause 9, wherein the amine-based scavengers are selected from: ethylenediamine dihydrochloride, polyallylamine hydrochloride, ethylenediamine diacetate, 4-aminobenzoic acid, 3-aminobenzoic acid, and combinations thereof.
17. The aerosol generating material according to clause 9, wherein the amino-acid-based scavengers are selected from: lysine, arginine, proline, methionine, L-cystine, and combinations thereof.
18. The extruded aerosol generating material according to any one of clauses 1 to 9, wherein the additive is diammonium phosphate.
19. The extruded aerosol generating material according to any one of clauses 1 to 18, wherein the additive is included in an amount of from about 0.01 wt% to about 5 wt%, based on the total weight of the extruded aerosol generating material.
20. The extruded aerosol generating material according to any one of clauses 1 to 19, further comprising a binder.
21. The extruded aerosol generating material according to clause 20, wherein the binder is selected from the list consisting of: modified starch, glucomannan, curdlan gum, amylopectin, HPMC, maltodextrin, carrageenan, xanthan gum, alginate, gum arabic, karaya gum, locust bean gum, gellan gum, agar, CMC, and combinations thereof.
22. The extruded aerosol generating material according to clause 20 or clause 21, wherein the extruded aerosol generating material comprises a mixture of at least two binders, optionally wherein the two binders are different.
23. The extruded aerosol generating material according to any one of clauses 20 to 22, wherein the total binder content is from about 10 wt% to about 20 wt%, based on the total weight of the extruded aerosol generating material.
24. The extruded aerosol generating material according to any one of clauses 1 to 23, further comprising a filler.
25. The extruded aerosol generating material according to clause 24, wherein the filler is CaCOs.
26. The extruded aerosol generating material according to clause 24 or clause 25, wherein the filler is included in an amount of less than about 10 wt%, based on the total weight of the extruded aerosol generating material.
27. The extruded aerosol generating material according to any one of clauses 1 to 26, further comprising an aerosol former.
28. The extruded aerosol generating material according to clause 27, wherein the aerosol former is selected from the list consisting of: glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, propylene carbonate, and combinations thereof.
29. The extruded aerosol generating material according to clause 27 or clause 28, wherein the aerosol former is included in an amount of from about 5 wt% to about 20 wt%, based on the total weight of the extruded aerosol generating material.
30. The extruded aerosol generating material according to any one of clauses 1 to 29, wherein the active is selected from nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof.
31. The extruded aerosol generating material according to any one of clauses 1 to 30, wherein the active is nicotine.
32. The extruded aerosol generating material according to any one of clauses 1 to 31, wherein the active is included in an amount from about 0.5 wt% to about 10 wt%, based on the total weight of the extruded aerosol generating material.
33. The extruded aerosol generating material according to any one of clauses 1 to 32, further comprising an acid.
34. The extruded aerosol generating material according to clause 33, wherein the acid is selected from the list consisting of: levulinic acid, lactic acid, benzoic acid, citric acid, 2-methylbutyric acid, 2-methylvaleric acid, and combinations thereof.
35. The extruded aerosol generating material according to clause 33 or clause 34, wherein the acid is a combination of levulinic acid and benzoic acid.
36. The extruded aerosol generating material according to any one of clauses 33 to 35, wherein the acid is included in an amount of at most 5 wt%, based on the total weight of the extruded aerosol generating material.
37. The extruded aerosol generating material according to any one of clauses 1 to 36, further comprising a monosaccharide and/or a disaccharide.
38. The extruded aerosol generating material according to clause 37, wherein the monosaccharaide and/or disaccharide are selected from: glucose, fructose, galactose, sucrose, lactose, and maltose, and combinations thereof.
39. An aerosol generating rod comprising an extruded aerosol generating material according to any one of clauses 1 to 38.
40. An article comprising the extruded aerosol generating material according to any one of clauses 1 to 38 or the aerosol generating rod according to clause 39.
41. A delivery system comprising the aerosol generating rod according to clause 39 or the article according to clause 40.
42. A process for preparing an extruded aerosol generating material, the process comprising:
- providing a composition comprising a fibrous material, an active and/or a flavourant, and an additive for scavenger carbonyls;
- mixing the composition to form a mixture; and
- extruding the mixture to form the extruded aerosol generating material.
43. Use of an additive for scavenging carbonyls in the preparation of an extruded aerosol generating material comprising a fibrous material and an active and/or a flavourant.
44. An aerosol generating material comprising:
- a non-tobacco botanical material,
- an active and/or flavourant, and
- a binder system comprising a first binder and a second binder,
- wherein a ratio of the non-tobacco botanical material to the binder system is from about 2:1 to about 4:1, and
- the first binder and the second binder are different.
45. The aerosol generating material according to clause 44, wherein the non-tobacco botanical material is selected from the list consisting of: eucalyptus, star anise, cocoa, hemp, rooibos, mint, fennel, and combinations thereof.
46. The aerosol generating material according to clause 44 or clause 45, wherein the non-tobacco botanical material is rooibos.
47. The aerosol generating material according to any one of clauses 44 to 46, wherein the non-tobacco botanical material is present in an amount of from about 30 wt% to about 55 wt%, based on the total weight of the aerosol generating material.
48. The extruded aerosol generating material according to any one of clauses 44 to 47, further comprising additive for scavenging carbonyls, wherein the additive is selected from the list consisting of: ammonium-based scavengers; polyphenol-based scavengers; anti-oxidant-based scavengers; organic acid-based scavengers; flavonoid and (ester) derivative-based scavengers; phenolic-based scavengers; amine-based scavengers; amino acid-based scavengers, and combinations thereof.
49. The extruded aerosol generating material according to clause 48, wherein the ammonium-based scavengers are selected from: diammonium phosphate, ammonium dihydrogen phosphate, ammonium magnesium phosphate, and combinations thereof.
50. The extruded aerosol generating material according to clause 48, wherein the polyphenol-based scavengers are selected from: chlorogenic acid and gallic acid.
51. The aerosol generating material according to clause 48, wherein the anti-oxidant-based scavenger is ferulic acid.
52. The aerosol generating material according to clause 48, wherein the organic acid-based scavenger is fumaric acid.
53. The extruded aerosol generating material according to clause 48, wherein the flavonoid and (ester)derivative-based scavengers are selected from: (+)-catechin hydrate, (-)-epicatechin, (-)-epigallocatechin gallate, and combinations thereof.
54. The aerosol generating material according to clause 48, wherein the phenolic-based scavengers are selected from: hydroxytyrosol, phloroglucinol dihydrate, and combinations thereof.
55. The extruded aerosol generating material according to clause 48, wherein the amine-based scavengers are selected from: ethylenediamine dihydrochloride, polyallylamine hydrochloride, ethylenediamine diacetate, 4-aminobenzoic acid, 3-aminobenzoic acid, and combinations thereof.
56. The aerosol generating material according to clause 48, wherein the aminoacid-based scavengers are selected from: lysine, arginine, proline, methionine, L-cystine, and combinations thereof
57. The aerosol generating material according to clause 48, wherein the additive is diammonium phosphate.
58. The aerosol generating material according to any one of clauses 48 to 57, wherein the additive is included in an amount of from about 0.01 wt% to about 5 wt%, based on the total weight of the extruded aerosol generating material.
59. The aerosol generating material according to any one of clauses 44 to 58, wherein the binder is selected from the list consisting of: modified starch, glucomannan, curdlan gum, amylopectin, HPMC, maltodextrin, carrageenan, xanthan gum, alginate, gum arabic, karaya gum, locust bean gum, gellan gum, agar, CMC, and combinations thereof.
60. The aerosol generating material according to any one of clauses 44 to 59, wherein the binders are selected from modified starch, glucomannan, and curdlan gum.
61. The aerosol generating material according to any one of clauses 44 to 60, wherein the total binder content is from about 10 wt% to about 20 wt%, based on the total weight of the aerosol generating material.
62. The aerosol generating material according to any one of clauses 44 to 61, further comprising a third binder.
63. The aerosol generating material according to any one of clauses 44 to 62, further comprising a filler.
64. The aerosol generating material according to clause 63, wherein the filler is CaCOs.
65. The aerosol generating material according to clause 63 or clause 64, wherein the filler is included in an amount of less than about 10 wt%, based on the total weight of the aerosol generating material.
66. The aerosol generating material according to any one of clauses 44 to 65, further comprising an aerosol former.
67. The aerosol generating material according to clause 66, wherein the aerosol former is selected from the list consisting of: glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, propylene carbonate, and combinations thereof.
68. The aerosol generating material according to clause 66 or clause 67, wherein the aerosol former is included in an amount of from about 5 wt% to about 20 wt%, based on the total weight of the aerosol generating material.
69. The aerosol generating material according to any one of clauses 44 to 68, wherein the active is selected from nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof.
70. The aerosol generating material according to any one of clauses 44 to 69, wherein the active is nicotine.
71. The aerosol generating material according to any one of clauses 44 to 70, wherein the active is included in an amount from about 0.5 wt% to about 10 wt%, based on the total weight of the aerosol generating material.
72. The aerosol generating material according to any one of clauses 44 to 71, further comprising an acid.
73. The aerosol generating material according to clause 72, wherein the acid is selected from the list consisting of: levulinic acid, lactic acid, benzoic acid, citric acid, 2-methylbutyric acid, 2-methylvaleric acid, and combinations thereof.
74. The aerosol generating material according to clause 72 or clause 73, wherein the acid is a combination of levulinic acid and benzoic acid.
75. The aerosol generating material according to any one of clauses 72 to 74, wherein the acid is included in an amount of at most 5 wt%, based on the total weight of the aerosol generating material.
76. The aerosol generating material according to any one of clauses 44 to 75, further comprising a monosaccharide and/or a disaccharide.
77. The aerosol generating material according to clause 76, wherein the monosaccharaide and/or disaccharide are selected from: glucose, fructose, galactose, sucrose, lactose, and maltose, and combinations thereof.
78. An aerosol generating rod comprising an aerosol generating material according to any one of clauses 44 to 77.
79. An article comprising the aerosol generating material according to any one of clauses 44 to 77 or the aerosol generating rod according to clause 78.
80. A delivery system comprising the aerosol generating rod according to clause 78 or the article according to clause 79.
81. A process for preparing an aerosol generating material, the process comprising:
- providing a composition comprising a non-tobacco botanical material, an active and/or flavourant, and a binder system comprising a first binder and a second binder;
- mixing the composition to form a mixture; and
- extruding the mixture to form the aerosol generating material,
- wherein a ratio of the non-tobacco botanical material to the binder system is from about 2:1 to about 4:1, and the first binder and the second binder are different.
82. Use of a binder system comprising a first binder and a second binder in the preparation of an aerosol generating material comprising a non-tobacco botanical material and an active and/or flavourant,
wherein a ratio of the non-tobacco botanical material to the binder system is from about 2:1 to about 4:1, and the first binder and the second binder are different.

Claims

An extruded aerosol generating material comprising:
a fibrous material,

an active and/or a flavourant, and

an additive for scavenging carbonyls.
The extruded aerosol generating material according to claim 1, wherein the fibrous material is a tobacco material.
The extruded aerosol generating material according to claim 2, wherein the tobacco material is included in an amount of greater than about 60 wt% based on the total weight of the extruded aerosol generating material.
The extruded aerosol generating material according to claim 1, wherein the fibrous material is a non-tobacco botanical material.
The extruded aerosol generating material according to claim 4, wherein the non-tobacco botanical material is selected from the list consisting of: eucalyptus, star anise, cocoa, hemp, rooibos, mint, fennel, and combinations thereof, optionally wherein the non-tobacco botanical material is rooibos.
The extruded aerosol generating material according to claim 4 or claim 5, wherein the non-tobacco botanical material is present in an amount of from about 30 wt% to about 55 wt%, based on the total weight of the extruded aerosol generating material.
The aerosol generating material according to any one of claims 1 to 6, further comprising an additive for scavenging carbonyls, wherein the additive is selected from the list consisting of: diammonium phosphate, ammonium dihydrogen phosphate, ammonium magnesium phosphate, chlorogenic acid, gallic acid, ferulic acid, fumaric acid, (+)-catechin hydrate, (-)-epicatechin, (-)-epigallocatechin gallate, hydrocytyrosol, phloroglucinol dihydrate ethylenediamine dihydrochloride, polyallylamine hydrochloride, ethylenediamine diacetate, lysine, arginine, proline, methionine, L-cysteine, 4-aminobenzoic acid, 3-aminobenzoic acid, ethylene glycol, glycerol, erythritol, threitol, arabitol, xylitol, ribitol, mannitol, sorbitol, galactitol, fucitol, iditol, inositol, volemitol, isomalt, maltitol, lactitol, maltotriitol, maltotetraitol, polyglycitol, and combinations thereof.
The extruded aerosol generating material according to any one of claims 1 to 7, wherein the additive is included in an amount of from about 0.01 wt% to about 5 wt%, based on the total weight of the extruded aerosol generating material.
The extruded aerosol generating material according to any one of claims 1 to 8, wherein the active is nicotine.
The extruded aerosol generating material according to any one of claims 1 to 9, further comprising an acid, optionally wherein the acid is selected from the list consisting of: levulinic acid, lactic acid, benzoic acid, citric acid, 2-methylbutyric acid, 2-methylvaleric acid, and combinations thereof, such as a combination of levulinic acid and benzoic acid.
An aerosol generating rod comprising an extruded aerosol generating material according to any one of claims 1 to 10.
An article comprising the extruded aerosol generating material according to any one of claims 1 to 10 or the aerosol generating rod according to claim 11.
A delivery system comprising the aerosol generating rod according to claim 11 or the article according to claim 12.
A process for preparing an extruded aerosol generating material, the process comprising:
providing a composition comprising a fibrous material, an active and/or a flavourant, and an additive for scavenger carbonyls;

mixing the composition to form a mixture; and

extruding the mixture to form the extruded aerosol generating material.
Use of an additive for scavenging carbonyls in the preparation of an extruded aerosol generating material comprising a fibrous material and an active and/or a flavourant.