EP4678019A1

EP4678019A1 - An aerosol generating material

Info

Publication number: EP4678019A1
Application number: EP24187800.8A
Authority: EP
Inventors: Peter Davis; Erik Reis; Maria Linhares de Andrade Rocha e Silva
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: WO2026013396A1

Abstract

An aerosol generating material comprising a non-tobacco botanical component, the non-tobacco botanical component comprising a stem material and a leaf material; and an active and/or a flavourant; wherein the aerosol generating material comprises less than about 10 wt% of stem material, based on the total weight of the aerosol generating material, and rods, articles, and delivery systems comprising such a 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 aerosol generating material comprising a non-tobacco botanical component, the non-tobacco botanical component comprising a stem material and a leaf material; and an active and/or a flavourant; wherein the aerosol generating material comprises less than about 10 wt% of stem material, based on the total weight of the aerosol generating material.
According to a second aspect, there is described an aerosol generating rod comprising an aerosol generating material according to the first aspect.
According to a third aspect, there is described an article comprising the aerosol generating material according to the first aspect or the aerosol generating rod according to the second aspect.
According to a fourth aspect, there is described a delivery system comprising the aerosol generating rod according to the second aspect or the article according to the third 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 perspective illustration of a non-combustible aerosol provision device for generating aerosol from the aerosol generating material of the article of Figure 1.

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 materials described herein may take any suitable form and may be in extruded form, reconstituted form, shredded, strips, strands, pellets, beads, cut strips, sheet form, a gathered sheet, or any other appropriate form in the field. The aerosol generating material may be manufactured by any appropriate method used in the field, such as extrusion, a paper-making process or a band casting method.
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.
In some embodiments, the aerosol generating material is in the form of a sheet or strips or strands and has a thickness of greater than about 80 µm, such as greater than about 100 µm, greater than about 150 µm, greater than about 200 µm, greater than about 250 µm, greater than about 300 µm, greater than about 350 µm, greater than about 400 µm.
In some embodiments, the aerosol generating material is in the form of a sheet or strips or strands and has a thickness of from about 80 µm to about 400 µm, such as from about 100 µm to about 400 µm, from about 150 µm to about 400 µm, from about 200 µm to about 400 µm, from about 250 µm to about 400 µm, from about 300 µm to about 400 µm. For example, the thickness may be from about 310 µm to about 390 µm. For example, the thickness may be from about 310 µm to about 380 µm. For example, the thickness may be from about 320 µm to about 370 µm. For example, the thickness may be from about 320 µm to about 360 µm. For example, the thickness may be from about 320 µm to about 350 µm. For example, the thickness may be from about 320 µm to about 340 µm. For example, the thickness may be from about 325 µm to about 340 µm. For example, the thickness may be from about 330 µm to about 340 µm.
In some embodiments, the aerosol generating material is in a reconstituted form. In some embodiments, the aerosol generating material is in a bandcast form.
The aerosol generating material comprises a non-tobacco botanical component.
In some embodiments, the non-tobacco botanical component is selected from a botanical material which comprises 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.
The non-tobacco botanical component may be selected from any suitable botanical material, such as: 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 component may be selected from eucalyptus, star anise, cocoa and hemp, rooibos, mint, fennel, and combinations thereof. For example, the non-tobacco botanical component 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 non-tobacco botanical component is included in an amount of from about 50 wt% to about 80 wt%, based on the total weight of the aerosol generating material. For example, the non-tobacco botanical component may be included in an amount of from about 55 wt% to about 80 wt%, such as from about 55 wt% to about 75 wt%, such as from about 60 wt% to about 75 wt%, such as from about 60 wt% to about 70 wt%, based on the total weight of the aerosol generating material.
In some embodiments, the non-tobacco botanical component is included in an amount of about 60 wt%, 61 wt%, 62 wt%, 63 wt%, 64 wt%, 65 wt%, 66 wt%, 67 wt%, 68 wt%, 69 wt%, 70 wt%, 71 wt%, 72 wt%, 73 wt%, 74 wt%, 75 wt%, 76 wt%, 77 wt%, 78 wt%, 79 wt%, 80 wt%, based on the total weight of the aerosol generating material.
In some embodiments, the non-tobacco botanical component 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 component 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 component 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.
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 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.
In the present invention, the non-tobacco botanical component comprises stem material and leaf material, wherein 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 stem material and the aerosol generating material comprises less than about 10 wt% stem, based on the total weight of the aerosol generating material. In some embodiments, the stem material comprises midrib and/or veins typically located on the leave of a non-tobacco botanical 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 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 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.
In some embodiments, the aerosol generating material further 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 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 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, 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/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 anti-oxidant-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 dihydrochloride, 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 eucolyptol, 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 from about 5 wt% to about 20 wt%, based on the total weight of the aerosol generating material. For example, the filler may be included in an amount of from about 7 wt% to about 20 wt%, from about 7 wt% to about 18 wt%, from about 8 wt% to about 18 wt%, from about 8 wt% to about 16 wt%, from about 8 wt% to about 14 wt%, from about 8 wt% to about 13 wt%, from about 8 wt% to about 12 wt%, based on the total weight of the aerosol generating material.
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 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 may comprise, or be, a continuous sheet of material. The sheet may be in the form one or more strands or strips of aerosol generating material.
In some embodiments, the aerosol generating material has a thickness of about 300 µm to about 400 µm. For example, the thickness may be from about 310 µm to about 390 µm. For example, the thickness may be from about 310 µm to about 380 µm. For example, the thickness may be from about 320 µm to about 370 µm. For example, the thickness may be from about 320 µm to about 360 µm. For example, the thickness may be from about 320 µm to about 350 µm. For example, the thickness may be from about 320 µm to about 340 µm. For example, the thickness may be from about 325 µm to about 340 µm. For example, the thickness may be from about 330 µm to about 340 µm.
In some embodiments, the aerosol generating material has a water content of between about 3% to about 8%. For example, the aerosol generating material has a water content of between about 4% to about 7%, for example between about 5% and about 6%. In some embodiments, the aerosol generating material comprises a water content of about 5%.
The aerosol generating material may be prepared by a papermaking process, including:

mixing a portion of non-tobacco botanical material with water in order to extract the water-soluble products contained therein;
the water-soluble extract is separated from the fibrous portion by physical separation
the fibrous portion is mixed and refined to produce a refined pulp, for example by chemically treating the fibrous portion
the refined pulp is passed into a papermaking machine in order to form a base sheet the sheet is impregnated with an active and/or flavourant; and
the impregnated sheet is dried to form an aerosol generating material.

In some embodiments, the extract from the non-tobacco botanical material is reintroduced into the base sheet.
The non-tobacco botanical material comprises less than 10 wt% stem material, based on the total weight of the aerosol generating material. The amount of stem material introduced into the process can be modified, such as by one of the methods discussed hereinabove.
In some embodiments, the sheet comprises refined pulp produced from the non-tobacco botanical material and refined pulp from a different source. For example, the sheet may further comprise refined pulp obtained from wood, hemp or cotton. The sheet may comprise refined pulp obtained from a different non-tobacco botanical material, therefore creating a blend/mix of different non-tobacco botanical materials.
In some embodiments, impregnating the sheet comprises spraying a solution onto the sheet. For example, the solution may be sprayed onto the sheet by an electric sprayer or using a compressed air sprayer.
In some embodiments, the sheet is impregnated with active by passing the sheet through a bath comprising a solution. The sheet may be fully submerged into the solution bath such that the sheet is impregnated with active. Submerging the sheet in a solution bath may result in greater coverage of active on the sheet compared to simply spraying the sheet with solution.
In some embodiments, the sheet may be passed through a solution bath and sprayed with solution. For example, the sheet may be fully submerged in a solution bath, removed, and subsequently sprayed with a solution. Alternatively, the sheet may be submerged in a solution bath, removed, dried, and subsequently sprayed with solution.
In some embodiments, the extract, active and/or flavourant may be combined with the refined pulp in the papermaking machine, e.g. added to the slurry prior to forming the base sheet.
The active may be dissolved in a solvent to form the solution. A suitable solvent system would be readily identifiable to a skilled artisan depending on the properties of the active. For example, a hydrophilic active may be dissolved in an aqueous solvent. Suitable solvents include water. A lipophilic active may be dissolved in an organic solvent.
The impregnated sheet may be dried in a drying device, such as in a commercial air/steam drier.
The aerosol generating material may be cut into sheets, strips similar to strips of tobacco, or rolled into a roll that could be cut into webs for inclusion in a delivery system.
In some embodiments, two or more sheets can be combined to form a laminate. For example, prior to drying, two or more sheets can be combined. For example, a first sheet may be combined with a second sheet made from the same non-tobacco botanical material to form a laminate. In some embodiments, a first sheet may be combined with a second sheet made from a different non-tobacco botanical material to form a laminate. Forming a laminate made from two different non-tobacco botanical materials may provide a desirable aerosol profile for a consumer. In some embodiments, a first sheet may be combined with a second sheet made from a tobacco material, such as a sheet of reconstituted tobacco. Combining a sheet made from a non-tobacco botanical material with a sheet made from tobacco material may enable the consumer to elevate the favourable/desirable aromas associated with an aerosol formed from a tobacco material.
The aerosol generating material may comprise, or be, a continuous sheet of material. The sheet may be in the form of a wrapper, it may be gathered to form a gathered sheet or it may be shredded to form a shredded sheet. The shredded sheet may comprise one or more strands or strips of aerosol generating material.
The strands or strips of material may be formed by shredding the sheet of aerosolisable material. The sheet of aerosolisable material may be cut width-wise, for example in a cross-cut type shredding process, to define a cut length for the strands or strips of aerosolisable material, in addition to a cut width. The cut length of the shredded aerosolisable material is preferably at least 5 mm, for instance at least 10 mm, or at least 20 mm. The cut length of the shredded aerosolisable material can be less than 60 mm, less than 50 mm, or less than 40 mm.
In some embodiments, the aerosol generating material may be prepared by combining the non-tobacco botanical material with an active and/or flavourant, a binder, and water to form a slurry. The slurry is subsequently processed to form a sheet of aerosolisable material. For example, the slurry may be processed by band casting it.
The slurry may be processed by forming a layer of the slurry on a surface and then drying the slurry to remove at least a portion of the water to form the sheet.
After drying, the sheet of aerosolisable material can be cut into strips or strands. The strips or strands of aerosolisable material can be gathered and formed into an article for use in a non-combustible aerosol provision system. A suitable process for cutting the sheet of aerosolisable material and gathering it into the article is found in WO 2019/057796 . Optionally, the aerosolisable material can be crimped prior to being gathered and formed into the article.
In some embodiments, the sheet of aerosol generating material is processed into a bobbin. This bobbin of aerosol generating material may then be fed into a shredding apparatus, to form strands/strips of aerosol generating material. Optionally, the aerosol generating material may be subject to a second cutting step, such as in a cross-cut type shredding process in order to obtain a defined cut length.
In some embodiments, the aerosol generating material may be prepared by processing the non-tobacco botanical material with a cellulose fibre. This process may comprise:

Providing a pre-sized particulate non-tobacco botanical material;
Providing pre-sized cellulose fibre;
Combining the pre-sized particulate non-tobacco botanical material with the pre-sized cellulose fibre to provide an initial material, wherein the initial material comprises at least 50%, such as 60-75%, by mass, of non-tobacco botanical material, and preferably 5-20%, by mass, of cellulose fibre;
Processing the initial material by setting the initial material to a predefined increased moisture content, subjecting the initial material to an increase in temperature and subjecting the initial material an increased pressure in order to bind the non-tobacco botanical material to the cellulose fibre;
Feeding the initial material through a shearing gap to form an aerosol generating material; and
Cooling the aerosol generating material.

Pre-sized particulate non-tobacco botanical material refers to material that has been subjected to a pre-sizing step prior to combining the botanical material with the cellulose fibre to form the initial material. The particle size reduction device may be a milling/cutting/shredding device. The size reduction device may be a disc mill. A hammer mill, or other milling device, may alternatively be used.
The pre-sizing step may comprise passing the non-tobacco botanical material through an appropriately sized sieve or series of sieves, and discarding, or processing to reduce the size of, any material that does not pass through the sieve or sieves, as appropriate.
It has been found that pre-sizing the non-tobacco botanical material to provide the required particle size or particle size distribution improves the quality of the produced aerosol generating material, including the organoleptic qualities of the component or product.
Adjusting the specific particle sizes or size distribution also provides an approach for controlling and adjusting the filling power and density of the resulting aerosol generating material.
During processing, the initial material is subjected to increased mechanical pressure and in particular also increased temperature and moisture. The initial material is brought to a pre-defined increased moisture content. The material to be processed is also subjected to an increase in temperature, which may be obtained in particular by applying heat from outside and/or by mechanically generating pressure. In some embodiments, the initial material is heated to a temperature of in the range of 60-180°C, such as 100-170°C, 120-160°C, or 130-150 °C.
This method of producing aerosol generating material has surprisingly been found to be advantageously performed at a lower expander pressure than that used in equivalent methods for processing tobacco material. Typically, corresponding tobacco processing methods require the use of expander pressures in the range of 35-50 bar. The production of equivalent materials comprising tobacco which do not include a binder typically require pressures of at least 60 bar, such as in the range of between 60 bar and 70 bar.
Advantageously, this processing method may comprise pressurising the initial material to a pressure in the range of 20-35 bar. This pressure is much lower than that used in the production of a corresponding material comprising only tobacco. Moreover, the use of lower pressures, such as less than 30 bar, or less than 25 bar, have been found to provide materials that are capable of carrying the greatest levels of aerosol forming materials.
As a result of the processing, the non-tobacco botanical material and cellulose fibre are bound together to produce an aerosol generating material that may be used subsequently for the production of aerosol provision systems. This obviates the need for expensive separate processes.
Due to the mechanical pressure, the particles of the non-tobacco botanical material and cellulose fibre are pressed and bound together. As a result of this, the binding of the materials is so strong that the resulting aerosol generating material is resistant to the normal stresses which occur during subsequent processing. For example, botanical fines are not lost from the material as it is being conveyed by air under normal production conditions. Mechanical stability is therefore higher than is the case with conventional tobacco film materials.
The use of smaller particles of non-tobacco botanical material, such as a higher proportion of botanical fines, in the initial material is advantageous because it means that small particles of botanical material, which are generally a waste by-product of manufacturing that would otherwise be disposed of, can instead be recycled and productively reused.
The use of smaller particles of non-tobacco botanical material in the initial material is also advantageous because it has been found to increase the filling power of the material, particularly in combination with the use of a binder.
The processing preferably results in a product which is an aerosol generating material, in particular a fibrous and/or granular material or filler material. In other words, the method results in a product which is ready for consumption and can be used directly in an aerosol provision system. This is very different from producing a smokable material film (continuous material), which is more complex to produce and which still has to be cut and dried after production. The product obtained as a result of the present disclosure is of a size and moisture content which make it suitable for use directly as a filler material for aerosol provision systems, including tobacco heating devices.
On leaving the shearing gap and entering the atmosphere, a proportion of the entrained water evaporates abruptly which, in addition to the shearing effect, causes the material to be expanded in the shearing gap. The moisture of the material is reduced to be in the range of 5-25% such as 7-20%, or 8-15% due to the flash evaporation, depending on the process pressure and temperature, and ingredients contained in the material are also reduced to a certain extent.
It has been found to be advantageous if the shearing gap surfaces are moved relative to one another to prevent and clear blockages. This ensures that the full cross-sectional surface of the gap is used and constant physical conditions prevail at the gap, which ultimately results in a uniform product. To this end, it has also proved to be of advantage if the gap surfaces are structured or profiled, for example, having grooves.
The aerosol generating material may be in an 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 material. For example, the extruded material may have the form of a cylindrical rod. Alternatively, the extruded 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 temperature 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 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 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 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.
As disclosed herein, a non-combustible aerosol-provision system may comprise the aerosol-generating material. This is exemplified in Figures 1 and 2.
Referring to Figure 1, the article 1 comprises a mouthpiece 2, and an aerosol-generating section 3, connected to the mouthpiece 2. In the present example, the aerosol-generating section 3 comprises the aerosol-generating material. The article 1 comprises a downstream end 2b and an upstream end 2a distal from the downstream end 2b.
In some embodiments, the aerosol generating material as described herein is provided in an aerosol generating section.
In the present example, the aerosol-generating material is circumscribed by a wrapper 5. In the present example, the wrapper 5 is a moisture impermeable wrapper. In some embodiments, the wrapper is paper, but may be made of alternative materials, such as aluminium.
The mouthpiece 2 includes a cooling section 6, also referred to as a cooling element, positioned immediately downstream of and adjacent to the source of aerosol-generating material 3. In the present example, the cooling section 6 is in an abutting relationship with the source of aerosol-generating material 3. The mouthpiece 2 also includes, in the present example, a body of material 7 downstream of the cooling section 6, and a hollow tubular element 8 downstream of the body of material 7, at the mouth end of the article 1.
Figure 2 shows an example of a non-combustible aerosol provision device 100 for generating aerosol from an aerosol-generating medium/material such as the aerosol-generating material of a consumable 110, as described herein. In broad outline, the device 100 may be used to heat a replaceable article 110 comprising the aerosol-generating medium, for instance an article 1 as illustrated in Figure 1 or as described elsewhere herein, to generate an aerosol or other inhalable medium which is inhaled by a user of the device 100. The device 100 and replaceable article 110 together form a system.
The device 100 comprises a housing 102 (in the form of an outer cover) which surrounds and houses various components of the device 100. The device 100 has an opening 104 in one end, through which the article 110 may be inserted for heating by a heating assembly. In use, the article 110 may be fully or partially inserted into the heating assembly where it may be heated by one or more components of the heater assembly.
The device 100 of this example comprises a first end member 106 which comprises a lid 108 which is moveable relative to the first end member 106 to close the opening 104 when no article 110 is in place. In Figure 2, the lid 108 is shown in an open configuration, however the lid 108 may move into a closed configuration. For example, a user may cause the lid 108 to slide in the direction of arrow "B".
The device 100 may also include a user-operable control element 112, such as a button or switch, which operates the device 100 when pressed. For example, a user may turn on the device 100 by operating the switch 112.
The device 100 may also comprise an electrical component, such as a socket/port 114, which can receive a cable to charge a battery of the device 100. For example, the socket 114 may be a charging port, such as a USB charging port.

Experimental

Extruded rods were manufactured having the formulations set out in Table 1.

Table 1

Consumable A		Consumable B
Rooibos*	53.6%	Rooibos*	53.6%
Modified Starch	6%	Modified Starch	6%
Glucomannan	5%	Glucomannan	5%
Curdlan Gum	3%	Curdlan Gum	3%
Glucose	3%	Glucose	3%
Nicotine mix*	18.9%	Nicotine mix*	18.9%
CaCO₃	4%	CaCO₃	4%
Propylene Glycol	2%	Propylene Glycol	2%
Glycerol	4.5%	Glycerol	4.5%

*The rooibos material incorporated into Consumable A included the full plant material, i.e. more than 10 wt% of stem/midrib/vein material. The rooibos material incorporated into Consumable B contained less than 10 wt% stem/midrib/vein 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 Table 2. Table 2

Sample Formaldehyde (µg/stick)

Consumable A 7.1

Consumable B 6.5
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 aerosol generating material comprising a non-tobacco botanical component, the non-tobacco botanical component comprising a stem material and a leaf material; and
- an active and/or a flavourant;
- wherein the aerosol generating material comprises less than about 10 wt% of stem material, based on the total weight of the aerosol generating material.
2. The aerosol generating material according to clause 1, wherein the non-tobacco botanical component is selected from the list consisting of: eucalyptus, star anise, cocoa, hemp, rooibos, mint, fennel, and combinations thereof.
3. The aerosol generating material according to clause 1 or clause 2, wherein the non-tobacco botanical component is rooibos.
4. The aerosol generating material according to any one of clauses 1 to 3, wherein the non-tobacco botanical component is present in an amount of from about 50 wt% to about 80 wt%, based on the total weight of the aerosol generating material.
5. The aerosol generating material according to any one of clauses 1 to 4, 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.
6. The aerosol generating material according to clause 5, wherein the ammonium-based scavengers are selected from: diammonium phosphate, ammonium dihydrogen phosphate, ammonium magnesium phosphate, and combinations thereof.
7. The aerosol generating material according to clause 5, wherein the polyphenol-based scavengers are selected from: chlorogenic acid and gallic acid,
8. The aerosol generating material according to clause 5, wherein the anti-oxidant-based scavenger is ferulic acid.
9. The aerosol generating material according to clause 5, wherein the organic acid-based scavenger is fumaric acid.
10. The aerosol generating material according to clause 5, wherein the flavonoid and (ester)derivative-based scavengers are selected from: (+)-catechin hydrate, (-)-epicatechin, (-)-epigallocatechin gallate, and combinations thereof.
11. The aerosol generating material according to clause 5, wherein the phenolic-based scavengers are selected from: hydroxytyrosol, phloroglucinol dihydrate, and combinations thereof.
12. The aerosol generating material according to clause 5, wherein the amine-based scavengers are selected from: ethylenediamine dihydrochloride, polyallylamine hydrochloride, ethylenediamine diacetate, 4-aminobenzoic acid, 3-aminobenzoic acid, and combinations thereof.
13. The aerosol generating material according to clause 5, wherein the amino-acid-based scavengers are selected from: lysine, arginine, proline, methionine, L-cystine and combinations thereof.
14. The aerosol generating material according to any one of clauses 5 to 13, wherein the additive is diammonium phosphate.
15. The aerosol generating material according to any one of clauses 5 to 14, 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.
16. The aerosol generating material according to any one of clauses 1 to 15, further comprising a filler.
17. The aerosol generating material according to clause 16, wherein the filler is cellulose, such as cellulose derived from wood pulp or CaCOs.
18. The aerosol generating material according to clause 16 or clause 17, wherein the filler is included in an amount of from about 1 wt% to about 20 wt%, based on the total weight of the aerosol generating material.
19. The aerosol generating material according to any one of clauses 1 to 18, further comprising an aerosol former.
20. The aerosol generating material according to clause 19, 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.
21. The aerosol generating material according to clause 19 or clause 20, 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.
22. The aerosol generating material according to any one of clauses 1 to 21, 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.
23. The aerosol generating material according to any one of clauses 1 to 22, wherein the active is nicotine.
24. The aerosol generating material according to any one of clauses 1 to 23, 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.
25. The aerosol generating material according to any one of clauses 1 to 24, further comprising an organic acid.
26. The aerosol generating material according to clause 25, wherein the organic 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.
27. The aerosol generating material according to clause 25 or clause 26, wherein the organic acid is: benzoic acid, levulinic acid, or a combination of levulinic acid and benzoic acid.
28. The aerosol generating material according to any one of clauses 5 to 27, wherein the organic acid is included in an amount of at most 5 wt%, based on the total weight of the aerosol generating material.
29. The aerosol generating material according to any one of clauses 1 to 28, further comprising a binder.
30. The aerosol generating material according to clause 29, 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.
31. The aerosol generating material according to clause 29 or clause 30, wherein the aerosol generating material comprises a mixture of at least two binders, optionally wherein the two binders are different.
32. The aerosol generating material according to any one of clauses 29 to 31, wherein the total binder content is from about 10 wt% to about 20 wt%, based on the total weight of the aerosol generating material.
33. The aerosol generating material according to any one of clauses 1 to 32, comprising less than about 5 wt% of stem material, based on the total weight of the aerosol generating material, such as less than about 2.5 wt%, less than about 2 wt%, less than about 1.5 wt%, less than about 1 wt%, less than about 0.5 wt%.
34. The aerosol generating material according to any one of clauses 1 to 33, wherein the aerosol generating material is substantially free of, or free of, stem material.
35. The aerosol generating material according to any one of clauses 1 to 34, wherein the aerosol generating material is in extruded form.
36. An aerosol generating rod comprising an aerosol generating material according to any one of clauses 1 to 35.
37. An article comprising the aerosol generating material according to any one of clauses 1 to 35 or the aerosol generating rod according to clause 36.
38. A delivery system comprising the aerosol generating rod according to clause 36 or the article according to clause 37.

Claims

An aerosol generating material comprising a non-tobacco botanical component, the non-tobacco botanical component comprising a stem material and a leaf material; and
an active and/or a flavourant;

wherein the aerosol generating material comprises less than about 10 wt% of stem material, based on the total weight of the aerosol generating material.
The aerosol generating material according to claim 1, wherein the non-tobacco botanical component 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 aerosol generating material according to claim 1 or claim 2, wherein the non-tobacco botanical component is present in an amount of from about 50 wt% to about 80 wt%, based on the total weight of the aerosol generating material.
The aerosol generating material according to any one of claims 1 to 3, 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 aerosol generating material according to claim 4, 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 aerosol generating material.
The aerosol generating material according to any one of claims 1 to 5, wherein the active is nicotine.
The aerosol generating material according to any one of claims 1 to 6, further comprising an organic acid, optionally wherein the organic 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.
The aerosol generating material according to any one of claims 1 to 7, further comprising an aerosol former.
The aerosol generating material according to claim 8, 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.
The aerosol generating material according to claim 8 or claim 9, 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.
The aerosol generating material according to any one of claims 1 to 10, further comprising a binder.
The aerosol generating material according to claim 11, 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.
An aerosol generating rod comprising an aerosol generating material according to any one of claims 1 to 12.
An article comprising the aerosol generating material according to any one of claims 1 to 12 or the aerosol generating rod according to claim 13.
A delivery system comprising the aerosol generating rod according to claim 13 or the article according to claim 14.