EP4734775A1

EP4734775A1 - Aerosol generating material

Info

Publication number: EP4734775A1
Application number: EP24740061.7A
Authority: EP
Inventors: Alina-Mariana CRAINIC; Benjamin Jenkins
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2023-06-30
Filing date: 2024-06-28
Publication date: 2026-05-06
Also published as: CN121865972A; GB202310026D0; WO2025003428A1

Abstract

Aerosol generating material The present disclosure relates to an aerosol generating material comprising a first surface and a second surface and indentations on the first surface and/or the second surface. A method for manufacturing the aerosol-generating material and articles comprising the aerosol-generating material are also disclosed.

Description

Aerosol generating material

Technical Field

The present disclosure relates to an aerosol-generating material, a method for manufacturing an aerosol-generating material and articles comprising aerosol- generating material.

Background

Aerosol provision products 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 substrate. Such an aerosol provision product commonly includes an aerosol-generating section or region, which generate an aerosol in use, and a mouthpiece through which the aerosol passes to reach the user’s mouth.

Such products suffer from the problem that the aerosol generating material is packed tightly into the product, which may make it relatively difficult for the user to draw air through the aerosol provision product. Consequently, the user may receive a poorer sensory experience.

Summary

According to a first aspect of the invention, there is provided an aerosol generating material comprising a first surface and a second surface and indentations on the first surface and/ or the second surface.

According to a second aspect of the invention, there is provided an aerosol generating material comprising one or more elongate strips, wherein each strip comprises a first surface and a second surface and indentations on the first surface and/ or the second surface. According to a third aspect of the invention, there is provided an aerosol generating material comprising a sheet, wherein the sheet comprises a first surface and a second surface and indentations on the first surface and/or the second surface. In some embodiments, the indentations have the shape selected from a group consisting of: circular, semi-circular, crescent, square, triangle, y-shape, lines, rectangle, cone or star.

In some embodiments, the indentations comprise a length and a width and an average width of the indentations of about o.oi to about 5 mm.

In some embodiments, the indentations have a length and a width, and wherein the length and the width have a length:width ratio of about 1:0.25 to about 1:10.

In some embodiments, the length of the aerosol generating material is at most about 34 mm. In some embodiments, each of the indentations have a volume of about 0.00001 mm3 to about 10 mm3.

In some embodiments, the average volume density of the aerosol generating material is from about 0.4 g/cm3 to about 1 g/cm3.

In some embodiments, the aerosol generating material comprises about 100 to about 500 indentations per cm².

In some embodiments, the thickness of the aerosol generating material is from about 100 pm to 350 pm.

In some embodiments, the thickness of the aerosol generating material increases by about 10 to 40%, compared to an equivalent material without the indentations. In some embodiments, the aerosol generating material has a tensile strength of at least 3 N/i5mm.

In some embodiments, the aerosol generating material comprises water.

In some embodiments, the aerosol generating material comprises a water content of 0% to about 15% by weight of the aerosol generating material. In some embodiments, the aerosol generating material comprises botanical material.

In some embodiments, the aerosol generating material comprises a botanical material content of from about 50 to about 80% by weight of the aerosol generating material. In some embodiments, the aerosol generating material comprises at least one binder.

In some embodiments, the aerosol generating material comprises a binder content of from 5 to about 40% by weight of the aerosol generating material.

In some embodiments, the aerosol generating material is in a form selected from a group consisting of: sheet, shredded sheet, gathered sheet , rod or strand.

According to a fourth aspect of the invention, there is provided an article for use in a non-combustible aerosol-provision system comprising an aerosol-generating section comprising the aerosol generating material according to any preceding claim.

In some embodiments, the article has a pressure drop between an upstream end and a downstream end of the article is from about 40 to about 120 mmWg.

In some embodiments, the article comprises an aerosol-generating section and a pressure drop across the aerosol-generating section is from 50 to about 500 mmWg.

According to a fifth aspect of the invention, there is provided a method of producing the aerosol generating material according to any one of claims 1 to 20, wherein the method comprises forming an aerosol-generating material composition, impressing recesses into a surface of the aerosol generating composition to form indentations in the surface and drying the aerosol generating composition to form the aerosol-generating material comprising the indentations.

In some embodiments, the aerosol generating material is prepared by extruding an aerosol generating composition.

According to a further aspect of the invention, there is provided an aerosol-generating material produced by the method of the fifth aspect.

Brief description of drawings

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

Figure 1 is a graph to show the affect of an aerosol generating material comprising indentations on the pressure drop of the material; Figure 2 is a magnified image of a first surface of an exemplary aerosol generating material comprising indentations;

Figure 3 is a graph to show the affect of an aerosol generating material comprising indentations on physical properties of the material; Figure 4 is a side-on cross-sectional view of an article for use with a non-combustible aerosol provision device;

Figure 5 is a perspective view of the article shown in Figure 4;

Figure 6 is a simplified schematic view of an exemplary rolling press; and

Figure 7 depicts schematically an exemplary process to make the aerosol generating material.

Detailed description

As used herein, the term “delivery system” is intended to encompass systems that deliver at least one substance to a user, and includes: combustible aerosol provision systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for roll-your-own or for make-your-own cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable material); 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; and aerosol-free delivery systems that deliver the at least one substance to a user orally, nasally, transdermally or in another way without forming an aerosol, including but not limited to, lozenges, gums, patches, articles comprising inhalable powders, and oral products such as oral tobacco which includes snus or moist snuff, wherein the at least one substance may or may not comprise nicotine.

According to the present disclosure, a “combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is combusted or burned during use in order to facilitate delivery of at least one substance to a user.

In some embodiments, the delivery system is a combustible aerosol provision system, such as a system selected from the group consisting of a cigarette, a cigarillo and a cigar. In some embodiments, the disclosure relates to a component for use in a combustible aerosol provision system, such as a filter, a filter rod, a filter segment, a tobacco rod, a spill, an aerosol-modifying agent release component such as a capsule, a thread, or a bead, or a paper such as a plug wrap, a tipping paper or a cigarette paper. The delivery system described herein can be implemented as a combustible aerosol provision system, a non-combustible aerosol provision system or an aerosol-free delivery system.

In a first aspect of the invention, an aerosol generating material comprising a first surface and a second surface and indentations on the first surface and/ or the second surface.

In a second aspect of the invention, there is provided an aerosol generating material comprising one or more elongate strips, wherein each strip comprises a first surface and a second surface and indentations on the first surface and/or the second surface.

In a third aspect of the invention, there is provided an aerosol generating material comprising a sheet, wherein the sheet comprises a first surface and a second surface and indentations on the first surface and/or the second surface.

An aerosol generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. The aerosol generating material may, for example, be in the form of a solid, liquid or semi-solid (such as a gel) which may or may not contain an active substance and/ or flavourants.

The aerosol-generating material may comprise one or more active substances and/or flavours, one or more aerosol-former materials, and optionally one or more other functional material.

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

The aerosol-generating film may have a thickness of about 0.015 mm to about 1 mm. For example, the thickness maybe in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm. The aerosol-generating film may be continuous. For example, the film may comprise or be a continuous sheet of material. The sheet maybe in the form of a wrapper, it maybe 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 aerosol-generating film may be discontinuous. For example, the aerosol-generating film may comprise one or more discrete portions or regions of aerosol-generating material, such as dots, stripes or lines, which may be supported on a support. In such embodiments, the support may be planar or non-planar.

The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-former and one or more other components, such as one or more substances to be delivered, to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the aerosolgenerating film.

The slurry maybe heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt% or 90 wt% of the solvent.

The aerosol-generating material may comprise or be an “amorphous solid”. In some embodiments, the aerosol-generating materiel comprises an aerosol-generating film that is an amorphous solid. The amorphous solid maybe a “monolithic solid”. The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the amorphous solid may, for example, comprise from about 50wt%, 6owt% or owt% of amorphous solid, to about 90wt%, 95wt% or ioowt% of amorphous solid.

The amorphous solid may be substantially free from botanical material. The amorphous solid maybe substantially tobacco free. The indentations on the first and/ or second surface may facilitate or increase the air flow through an aerosol generating section of an article incorporating the aerosol generating material. This may improve the flavour provided to the user of the delivery system. This may also reduce the pressure drop across the aerosol generating material when in use. The aerosol generating material may be in the form of a sheet, a shredded sheet, gathered sheet, rod or strand. The aerosol generating material may comprise or be in the form of elongate strips. Each sheet, shredded sheet, strand and/or strip may comprise a first surface and a second surface and indentations on the first surface and/or the second surface. The form of the aerosol generating material maybe selected to provide the appropriate flavour and experience to the user. For example, in embodiments comprising tobacco, some forms of the aerosol generating material may be selected to provide a similar experience to tobacco. The form of the aerosol generating material also has an effect on the surface area to volume ratio, thereby also affecting the flavour delivered to the user. In some embodiments, the first and second surfaces may be on opposing sides of the sheet, shredded sheet or elongate strips.

In some embodiments, the indentations cover a portion of the first and/ or second surface. The indentations may cover up to about 10%, up to about 25%, up to about 50%, up to about 75%, up to about 90%, or up to about 100% of the first and/or second surface by surface area. In some embodiments, the portion or area with indentions covers all of the first and second surfaces of the aerosol generating material.

In some embodiments, the surface maybe sparsely populated with indentations and in other embodiments the surface maybe densely populated by the indentations. In some embodiments, the number of indentations is about 1 to about 2000, about 5 to about 1000, about 10 to about too per cm². In some embodiments, the number of indentations is about too to about 500 or about 200 to about 300 indentations per cm². The number of indentations per cm² affects the air flow, packing, fill value and flavour delivery of the aerosol generating material.

In some embodiments, sections of the first and/ second surface comprise indentations.

Said indentations maybe of any suitable size or shape, and may form a pattern on the surface. For example, the sections may form a “stripe” pattern on the surface of the aerosol generating material, wherein there is a section comprising indentations adjacent to a section which does not comprise such indentations. This provides the advantage that pattern of the indentations can be controlled, which may have an effect on air flow, pressure drop and flavour delivery to the user as described herein. The sections may also form other patterns which may be visually appealing.

It has been found that, for a given volume of an aerosol-generating material, a similar pressure drop across the article can be achieved by replacing some or all of this aerosolgenerating material with a lower mass of the aerosol-generating material with indentations described herein. Not only that, the hardness of the aerosol-generating material may be maintained at these lower masses.

The indentations may be of any suitable size and/or volume, but may be selected to provide the advantages described herein. The heights, widths and lengths disclosed herein may also be the average heights, widths and lengths respectively.

In some embodiments, the indentations have a length and a width. As used herein, the term “length of indentation” may be measured as the longest distance across an indentation. As used herein, the term “width of indentation” denotes a dimension in a direction transverse to the length. In some embodiments, the length and the width have a ratio of about 1:0.25 to about 1:10, of about 1:0.5 to about 1:5, of about 1:0.75 to about 1:2, or of about 1:1. For example, in embodiments in which the indentation has a substantially circular or square shape, the length and width of the indention may be substantially the same and the length and the width have a ratio of about 1:1.

In some embodiments, the length of the indentations is from about 0.01 to about 5 mm, from about 0.1 to about 1 mm, or from about 0.5 to about 0.8 mm. In some embodiments, the length of the indentations is from about 0.1 mm to about double the thickness of the sheet. For example, if the sheet is 0.2 mm thick, the length of the indention may be up to 0.4 mm. In some embodiments, the length of the indentations is about 0.5 mm. The indentations may have any suitable volume, but may be selected to provide the advantages described herein. The length and the width of the indentation may be selected to provide a suitable volume. In some embodiments, the indentations each have a volume of about 0.00001 to about to mm3. j_n some embodiments, the indentations have a volume of about 0.001 to about to mm3, o.oi to about i mm3, o.oi to about 0.5 mm3.

The larger the height and width (and therefore the volume) of an indentation, the higher the air flow and pressure drop across the aerosol generating material. This provides a more pleasant user experience when the aerosol generating material is used in an article in a delivery system. Furthermore, the fill value of the aerosol generating material is increased and thereby improved. For example, the indentations can reduce the density of the aerosol generating material, meaning that the same mass of the material takes up more volume. This is advantageous for transport of the material and for packing in the article. It is also advantageous to have a higher fill value in the delivery system itself.

The “fill value” (also known as “filling value”) is a measure of the ability of a material to occupy a specific volume at a given moisture content. The fill value is measured using a densimeter, wherein the volume occupied by unit weight of the material or composition is measured. A high fill value indicates that a lower weight of material is required to produce a rod at acceptable hardness/firmness levels of a given circumference, volume and length than is required with a material of lower fill value.

In some embodiments, the aerosol-generating material may have a fill value of from about 3 to about 8 cc/g, about 4 to about 8 g/cc, or about 4.5 to about 5.5 cc/g.

The invention enjoys the benefit of the further advantage that the indentations do not affect the hardness, resilience, softness or weight of the of the aerosol generating material. This means that the aerosol generating material may be used in known noncombustible aerosol generating devices without significant alteration of the device to accommodate the aerosol generating material.

Figure 1 shows data from trials using Material A and Material B. Material A comprised a sheet of extruded aerosol generating composition. Material B comprised an exemplary embodiment of the aerosol generating material as described herein, comprising indentations on a first surface. Materials A and B are in the form of a sheet, with a thickness of 160 pm and area density of 172 g/m². Materials A and B comprise the same composition, including a particle size distribution (D90) of about 70pm, and are otherwise the same with the exception of the indentations, and are otherwise the same with the exception of the indentations. Figure 1 demonstrates that the hardness, softness and resilience, measured in percent, remain substantially the same.

The number of indentations per cm3 _on the aerosol generating material may be selected to provides the advantages. The number of indentations per cm3 _may be from about 1 to about 1000, from about too to about 500, from about 200 to about 300, from about 1 to about too, from about 1 to about 50 or from about 1 to about 20 indentions per cm². It has been found that the number of indentations per cm3 and volume of indentations has an effect on the thickness of the aerosol generating material. The larger the number and volume of indentations, the thicker the aerosol generating material may be. In some embodiments, the indentations increases the thickness of the aerosol generating material by about 10 to 40%, about 20 to 30% or by about 25% compared to the thickness of the aerosol generating material before the indentations were impressed.

For example, in embodiments wherein the aerosol generating material is in the form of a sheet, shredded sheet or elongate strip, the average thickness may be about 160 to 190 pm in thickness prior to being impressed with indentations and increased to about 200 pm with the indentations. In another example, in embodiments wherein the aerosol generating material is in the form of a sheet, shredded sheet or elongate strip, the average thickness maybe about 250 pm in thickness prior to being impressed with indentations and increased to about 310 pm with the indentations. In some embodiments, a higher number and larger volumes of indentation are associated with thicker sheets. In some embodiments, the thickness of the aerosol material is from about too pm to 350 pm, from about 160 pm to 250 pm, from about 160 pm to 200 pm, from about 160 pm to about 310 pm, or from about 280 pm to about 310 pm. The thickness maybe measured based on measurements from pieces of material, using a hand calliper.

It is thought that as a result of the increased thickness of the aerosol generating material, the density of the material is reduced. This is because the material has a larger volume but the same mass or weight. This is advantageous because the aerosol generating material is lighter, which has advantages for transport and storage of the material, and also for the consumer as the article into which the aerosol generating material is packed may be lighter.

In some embodiments, the sheet or shredded sheet of aerosol-generating material has an area density of from about too g/m² to about 300 g/m², or from about 150 to about 210 g/m². The sheet or shredded sheet may have an area density of from about 110 g/m² to about 280 g/m², from about 120 g/m² to about 260 g/m², from about 130 g/m² to about 240 g/m² or from about 140 g/m² to about 220 g/m². In some embodiments, the sheet or shredded sheet has an area density of from about 190 g/m².

The average volume density or grammage of the sheet or shredded sheet of aerosol- generating material may be calculated from the thickness of the sheet and the area density of the sheet. In some embodiments, average volume density or grammage may be greater than about 0.4 g/cm3, about 0.6 g/cm3 _or about 0.7 g/cm3. j_n some embodiments, the average volume density is from about 0.4 g/cm3 to about 1 g/cm3, from about 0.4 g/cm3 to about 0.8 g/cm3, _Or from about 0.5 g/cm3 to about 0.7 g/cm3. In some embodiments, the indentations are perforations. A perforation is when the indentation forms a hole through the aerosol generating material. This provides the advantage that air flow is further increased through the aerosol generating material and this in turn reduces the pressure drop and draw resistance. Such perforations also further increase the airflow and flavour delivery to the user. In some embodiments, the aerosol generating material comprises a mixture of both perforations and indentations on the first and/or second surface. The aerosol generating material may comprise up to about 10%, about 20%, about 30%, about 40% or about 50% perforations compared to indentations on the first and/or second surface.

The perforations maybe from about 0.01 to about 1 mm in diameter. The perforations may be from about 1 to about 300 pm, from about 10 to about too pm from about 50 to about 150 pm, from about 70 to about too pm in diameter.

The invention enjoys the advantage that the surface area to volume ratio is increased compared to an aerosol generating material without indentations. The surface area to volume ration also increases with the amount, size and shape of the indentations. This provides the advantage that a higher surface to volume ratio is associated with a stronger and more prolonged flavour delivery to the user from the aerosol generating material. It has been found that the quantity and size of indentations has an effect on the tensile strength of the aerosol generating material. For example, too many indentations or too large a size of indentation may cause a reduction in the tensile strength of the aerosol generating material and result in the material losing its structure. On the other hand, the quantity and size of indentations must be sufficient to provide the desired advantages. In some embodiments, the tensile strength of the aerosol generating material is increased in order to accommodate a higher amount and/or size of indentations. For example, the quantity of binder or filler may be adjusted as described herein. In some embodiments, the aerosol generating material has a tensile strength of from about i to about 30 N/ismm, from about 5 to about 20, from about 8 to about 15, or from about 9 to about 13 N/ 15mm. In some embodiments, the aerosol generating material has a tensile strength that is greater than about 5 N/ 15mm. In some embodiments, the aerosol generating material has a tensile strength of at least 3 N/ 15mm or at least 4 N/ 15mm.

In some embodiments, wherein the first and the second surface comprise indentations, the number, density, size or shape of the indentations maybe different. This provides the advantage that the airflow may be controlled when the aerosol generating material is put in the consumable. On the other hand, in some embodiments, the indentations are of a suitable size and shape that the aerosol generating material can interlock. This is particularly advantageous in embodiments in which the aerosol generating material is in the form of a shredded sheet and elongate strips. In such embodiments, the surface without indentations may be aligned with indentations so that the aerosol generating material interlocks. This increases packing of the aerosol generating material and reduces the air flow and pressure drop. The size, shape and pattern of the indentations may also be selected to prevent interlocking of the aerosol generating material.

The aerosol-generating material may have a packing density of between about 400 mg/cm3 and about 900 mg/cm3 within the aerosol-generating section. A packing density higher than this may increase the pressure drop.

The packing density has an effect on the flavour delivery. As more aerosol-generating material is packed into the consumable, a stronger flavour may be delivered to the user. On the other hand, a higher packing density reduces the air flow, and increase the pressure drop and resistance to draw for the user.

The indentations may be of any suitable shape. In some embodiments the shape is selected from a group consisting of: circular, semi-circular, crescent, square, triangle,

Y-shape, lines, rectangle, cone or star. The shape maybe selected to provide suitable airflow, pressure drop and flavour provision properties, whilst maintaining an adequate tensile strength. For example, a circular shape has been found to provide particularly suitable parameters, including improved air flow and air permeability. Some shapes may tessellate, allowing for surface to be more densely populated with the indentations.

Figure 2 shows a magnified image of a first surface of an exemplary aerosol generating material comprising indentations. In this exemplary embodiment, the shape of the indentation is circular.

In some embodiments, the aerosol generating material formed from an aerosol generating composition, wherein the aerosol generating composition is extruded. The aerosol generating material prepared in this method has specific elasticity properties that make the material particularly suitable for being impressed with indentations.

More specifically, such aerosol generating materials retain the indentations for a longer period of time. In contrast an aerosol generating material formed using a band casting method is less elastic and retains the shape of the for a shorter period of time.

The period of time that the aerosol generating material retains the indentations is also affected by the water, binder, filler, botanical material content and particle size in the aerosol generating composition and/or the aerosol generating material. These maybe selected to provide a suitable aerosol generating composition to impress with indentations, as well as provide a pleasant flavour delivery to the user.

In some embodiments of the invention, the aerosol generating composition and/ or the aerosol generating material comprises a binder. The binder may be selected from one or more compounds selected from the group comprising alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica or silicones compounds, clays, polyvinyl alcohol and combinations thereof. For example, in some embodiments, the binder comprises one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose (CMC), pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol. In some cases, the binder comprises alginate and/or pectin or carrageenan. In some embodiments, the binder comprises CMC.

In some embodiments, the aerosol generating composition and/or the aerosol generating material comprises a binder content of from 5 to about 40% by weight. In some embodiments, aerosol generating material and/or aerosol generating composition may comprises a binder content of about 5 to about 30%, about 5 to about 20%, about 5 to about 15%, or about 5 to about 10% by weight.

In some embodiments, the aerosol generating composition and/or the aerosol generating material comprises a botanical material. In some embodiments, the botanical material comprises or consist of one or more botanicals or constituents, derivatives or extracts thereof. In some embodiments, the aerosol generating material does not comprise a botanical material.

As used herein, the term "botanical" includes any material derived from plants or plant material including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. In some embodiments, the botanical material is plant derived material or plant material that has been cut into smaller pieces, for example the plant derived material or plant material may be milled, pulverised, dices, slices, or otherwise partitioned to reduce the size of the pieces. In some embodiments, the botanical material is plant derived material or plant material in the form of particles.

In some embodiments, the botanical material comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is tobacco. In some embodiments, the aerosol generating composition does not comprise tobacco. In embodiments, the aerosol generating composition may comprise a botanical material that does not comprise or consist of tobacco. In such embodiments, the botanical material may be selected to be non-tobacco to be desirable to the consumer or for regulatory reasons. The botanical material maybe selected to provide a pleasant or desirable flavour to the consumer.

In some embodiments, the botanical material comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from eucalyptus, star anise, cocoa and hemp. In some embodiments, the botanical is selected from rooibos and fennel. Rooibos and tobacco may be preferred botanical materials.

Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material maybe in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like. Combining one, or more, non-tobacco botanical materials with an active may allow for the sensory properties attributable to the active (such as nicotine or menthol) to be more readily perceived by the user compared with tobacco-based aerosol-generating materials. As a consequence, any variations in the consistency of the aerosolgenerating material may be more detectable by the user when the aerosol-generating material is heated to produce an aerosol. Therefore, it is desirable to ensure that both the non-tobacco botanical and the active are homogeneously mixed throughout the aerosol-generating material to achieve a product having consistent aerosol properties. In some embodiments, the botanical material is tobacco material. Thus, in some embodiments, the aerosol-generating material comprises tobacco. In some embodiments, the aerosol-generating material does not comprise tobacco. In some embodiments, the aerosol-generating material does not comprise tobacco material is substantially tobacco free.

The aerosol generating composition and/ or the aerosol generating material may be substantially free from botanical material. In particular, in some embodiments, the aerosol generating composition and/or the aerosol generating material is substantially tobacco free. As used herein, the term “tobacco material” refers to any material comprising tobacco or derivatives or substitutes thereof. The tobacco material may be in any suitable form. The term “tobacco material” may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, paper reconstituted tobacco, or tobacco substitutes. The tobacco material may comprise one or more of ground tobacco, tobacco fibre, cut tobacco, extruded tobacco, tobacco stem, tobacco lamina, reconstituted tobacco and/or tobacco extract.

In some embodiments, the aerosol generating composition and/or the aerosol generating material comprises at least about 10 wt% of the botanical material. In some embodiments, the aerosol generating material comprises at least 40 wt%, at least about 50 wt%, at least about 60 wt%, at least about 75 wt%, at least about 95 wt%, at least about 99 wt% of the botanical material. In some embodiments, the aerosol generating material substantially consists of the botanical material. The botanical material content may be selected to provide a positive flavour to the user and to provide a suitable texture in the aerosol generating material. The botanical material content affects the elasticity and the tensile strength in the aerosol generating material.

In some embodiments, the aerosol generating composition and/or the aerosol generating material comprises at most about 10 wt% of the botanical material. In some embodiments, the aerosol generating material does not comprise a botanical material. In some embodiments, the aerosol generating composition and/or the aerosol generating material comprises at most about 60 wt%, at most about 75 wt%, at most about 80 wt%, at most about 95 wt%, at most about 99 wt% of the botanical material.

For example, the botanical material may be present in an amount of about 50%, 60%, 70%, 80%, or 90% by weight of the the aerosol generating composition and/ or the aerosol generating material. The botanical material may be present in an amount of from about 50 to about 80% by weight of the aerosol generating composition and/or the aerosol generating material.

The botanical material maybe a particulate or granular material. In some embodiments, the botanical material is a powder or may be ground. Alternatively or in addition, the botanical material may comprise strips, strands or fibres of tobacco. For example, the botanical material may comprise particles, granules, fibres, strips and/or strands of botanical material. In some embodiments, the botanical material consists of particles or granules of botanical material. In some embodiments, the botanical material is in a particulate or ground form, as this assists with the formation of a dough-like material that is formed when the first and second compositions are combined.

In embodiments in which the botanical is a particulate botanical material, each particle of the particulate botanical material may have a maximum dimension. As used herein, the term “maximum dimension” refers to the longest straight-line distance from any point on the surface of a particle of botanical, or on a particle surface, to any other surface point on the same particle of botanical, or particle surface. The maximum dimension of a particle of particulate botanical material may be measured using scanning electron microscopy (SEM).

In some embodiments, the maximum dimension of each particle of botanical material is up to about 800 pm. In some embodiments, the maximum dimension of each particle of botanical material is up to about 2000 pm. In some embodiments, the maximum dimension of each particle of botanical material is about 200 pm to about 800 pm.

A population of particles of the botanical material may have a particle size distribution (D90) of at least about 70 pm. In some embodiments, a population of particles of the botanical material has a particle size distribution (D90) of at least about 50 pm, of at least about 60, of at least about 70 pm, of at least about 80 pm, of at least about 90, of at least about 100 pm, of at least about 110 pm, of at least about 120 pm, of at least about 130 pm. In some embodiments, a population of particles of the botanical material has a particle size distribution (D90) of at most about 720 pm, of at most about 740 pm, of at most about 760 pm, of at most about 780 pm, of at most about 800 pm, of at most about 820 pm, of at most about 840 pm, of at most about 860 pm. In some embodiments, a population of particles of the botanical material has a particle size distribution (D90) of about 600 pm. A particle size and shape analyser, such as a Camsizer maybe used to measure the particle size distribution, and sieve analysis may be used to determine the particle size distribution of the particles of botanical material.

It has been found that the particle size distribution (D90) may be controlled to achieve the desired tensile strength of the aerosol-generating material. For example, higher particle size distributions (D90) are associated with lower tensile strengths. Without wishing to be bound by reason, when the particle size distribution is lower, there is more material to be bound together. This may make the aerosol-generating material stronger and so the tensile strength is higher. The D90 may therefore be used to optimise the tensile strength of the aerosol generating material. This is particularly important because the higher amounts and larger sizes of the indentations in the aerosol generating material can lower the tensile strength. In some embodiments, the aerosol generating material comprises a filler. In some embodiments, aerosol generating material has a filler content of from about o % to about 20 %, about 1 to about 15%, about 3 to about 10%, or about 4 to about 6% by weight. The filler is generally a non-botanical component, that is, a component that does not include ingredients or components originating from tobacco. The filler may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate, and suitable inorganic sorbents, such as molecular sieves. The filler may be a non-tobacco fibre such as wood fibre or pulp or wheat fibre. The filler can be a material comprising cellulose or a material comprises a derivate of cellulose. The filler component may also be a non-tobacco cast material or a non-tobacco extruded material. In some embodiments, the filler is cellulosic material, cellulose or CMC. In some embodiments, the filler is essentially composed or consists of cellulose.

In particular embodiments which include filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood, wood pulp, hemp fibre, cellulose or cellulose derivatives. Without wishing to be bound by theory, it is believed that including fibrous filler may increase the tensile strength of the aerosol-generating material that is formed. This is advantageous because this can balance the decreased tensile strength caused by the indentations.

The filler may also contribute to the texture of the aerosol-generating material. For example, a fibrous filler, such as cellulose, may provide an aerosol-generating material having relatively rough first and second surfaces. Conversely, a non-fibrous, particulate filler, such as powdered chalk, may provide an aerosol-generating material having relatively smooth first and second surfaces. In some embodiments, the aerosolgenerating material comprises a combination of different filler materials. The filler may help to improve the general structural properties of the aerosol-generating material, such as its tensile strength and burst strength. In some embodiments, the aerosol-generating material comprises water. The aerosolgenerating material may comprise water in an amount of less than about 20%, less than about 15%, less than about 10% or less than about 5% by weight of the aerosolgenerating material. In some embodiments, the aerosol-generating material comprises water in an amount of between about 0% and about 15% or between about 5% and about 15% by weight of the aerosol-generating material. The amount of water affects the texture and tensile strength of the material, and maybe selected to provide adequate properties for its useability. The water content of the aerosol-generating material described herein may vary according to, for example, the temperature, pressure and humidity conditions at which the compositions are maintained. The water content can be determined by Karl-Fisher analysis, as known to those skilled in the art. In some embodiments the aerosol generating material comprises a flavour. In some embodiments, the aerosol generating material may comprise a flavour content of about o to about 20% by weight. The aerosol generating material may have a flavour content of from about o to about 20 %, about 5 to about 20 %, about 5 to about 15 %, about 8 to about 12%. The flavour content may be selected to deliver a suitable flavour to the consumer, but not to negatively impact the other properties of the 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 maybe 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.

In some embodiments, the aerosol generating material delivers a substance to the user.

In some embodiments, the substance to be delivered to the user comprises an active substance.

The active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, 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 maybe CBD or a derivative thereof. In one embodiment the active substance is a legally permissible recreational drug

In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12. As noted herein, the active substance may comprise one or more constituents, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.

In some embodiments of the invention, the aerosol generating material does not comprise tobacco. In such embodiments, the aerosol generating material may comprise a plant material or botanical or other substance to be delivered to the user.

In another aspect of the invention, there is provided an article for use in a noncombustible aerosol-provision system comprising an aerosol-generating section comprising the aerosol generating material.

A consumable or article is an article comprising or consisting of aerosol-generating material, part or all of which is intended to be consumed during use by a user. An article may comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and/ or an aerosolmodifying agent. An article may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate aerosol in use. The heater may, for example, comprise combustible material, a material heatable by electrical conduction, or a susceptor.

The invention provides the advantage that the aerosol generating material provides an improved pressure drop across the aerosol-generating section. Advantageously, compared to other aerosol generating materials, the inventive aerosol generating material may have a lower the mass with the same pressure drop. The aerosol generating material may therefore be of a lower mass, but maintain a suitable pressure drop. This results in a lighter article for use and storage. Without wishing to be bound by any particular theory, the indentations may provide increased airflow around the aerosol generating material, thereby increasing the pressure drop across the aerosol generating material and/or the section comprising said material.

In some embodiments, the pressure drop across the article is about 40 to about 120 mmWg, about 50 to about 90 mmWg, about 60 to about 80 mmWg, or about 30 to about 50 mmWg. The pressure drop maybe measured between an upstream end and a downstream end of the article. In some embodiments, the pressure drop across the article is greater than 35, about 40, about 50 about 60 or about 70 mm Wg. In some embodiments, the pressure drop across the aerosol-generating section is about too to about 500, about 150 to about 300, about 180 to about 250, or about 200 to about 220 mmWg. In some embodiments, the pressure drop across the aerosolgenerating section is about 350 to about 600 mmWg, about 400 to about 5800 mmWg, or about 500 to about 550 mmWg.

Figure 3 shows data from trials using Material A and Material B. Material A comprised a sheet of extruded aerosol generating composition. Material B comprised an exemplary embodiment of the aerosol generating material as described herein, comprising indentations on a first surface. Materials A and B are in the form of a sheet, with a thickness of 160 pm and area density of 172 g/m². Materials A and B comprise the same composition, including a particle size distribution (D90) of about 70pm, and are otherwise the same with the exception of the indentations. Figure 3 demonstrates that the pressure drop across the aerosol-generating section is higher when the material comprises indentations. In some embodiments of the invention, an article for use with a non-combustible aerosol-provision system comprises the aerosol generating material. In some embodiments, the article comprises more than one aerosol generating material. In such embodiments, the aerosol generating materials may have different indentations (or compositions) to after the air flow through the article. This affects the flavour delivered to the user and the pressure drop across the article.

Referring to Figures 4 and 5, the article 1 comprises a mouthpiece 2, and an aerosolgenerating 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.

A pressure drop across the aerosol-generating section of an article comprising the aerosol-generating material may be between about 0.3 and 5 mmWG per mm of length of the aerosol-generating section. The pressure drop can between 0.5 mmWG and 2 mmWG per mm of length of the aerosol-generating section. The pressure drop can, for instance, be between 0.5 and 1 mmWG/mm of length, between 1 and 1.5 mmWG/mm of length or between 1.5 and 2 mmWG/mm of length of the aerosol-generating section.

The total pressure drop across the article can, for instance, be between 60 mmWG and 120 mWG, or between 70 mmWG and 110 mmWG. It has been found that the indentations are associated with an increased pressure drop. That is to say that the aerosol-generating material can increase the pressure drop compared with an article that comprises aerosol-generating material without indentations. This means that the mass of the aerosol-generating material can reduced whilst retaining a preferred pressure drop. This results in an improved pressure drop whilst in use and can increase the strength and longevity of the flavours that are produced. In addition, the pressure drop is associated with the resistance to draw, and this can provide improved experience to the consumer.

When in use, the article may exhibit a pressure drop of from about 15 to about 40 mm H₂0. In some embodiments, the aerosol-generating section exhibits a pressure drop across the aerosol-generating section of from about 15 to about 30 mm H₂0.

In another aspect of the invention, there is provided a method to make the aerosol generating material in which the aerosol generating material is impressed with recesses on its surface to form the indentations. 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. The wrapper 5. In some embodiments, the wrapper is paper, but maybe 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 aerosolgenerating 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. The aerosol generating material maybe impressed using any suitable means. Such means include rollers, presses, stamps for example. Such apparatus may have the shape of the indentation embossed upon at least one surface and used to impress said shape onto the surface(s) of the aerosol generating material. In some embodiments, wherein the first and the second surface comprise indentations, than one apparatus may be used to simultaneously impress indentations in the surface simultaneously. This provides the advantage of impressing the indentations in less time.

An exemplary rolling press is illustrated schematically in Figure 6. Rolling press 102 comprises two rollers 106. The rollers 106 have a space 103 through which the material 101 moves, impressing indentations on said material.

The advantage of using a roller is that this is a continuous process, wherein the aerosol generating material may be fed into rollers or a rolling press and impressed with indentations.

The rolling process also provides the aerosol generating material with a consistent thickness. This, along with the volume and shape of the indentations, has an effect on the air flow and pressure drop.

In some embodiments, the aerosol generating material is prepared from an aerosol generating composition comprising combining a first composition and a second composition to form a mixture of the first composition and the second composition and processing the mixture of the first composition and the second composition to form the aerosol generating material.

The first composition, also known as the “wet mixture”, comprises an aerosol former or humectant and a binder. The first composition may also comprise other liquids or suspensions disclosed herein. The first composition may be in a liquid phase. The second composition, also known as the “dry mixture”, comprises a tobacco material, a filler and optionally a second binder. The second composition may also comprise other solids or gels disclosed herein. The second composition may be in the solid phase.

The amount of binder in the first composition, second composition and mixture of the first and second compositions is important as this alters the consistency of the compositions and mixtures. Too much binder may cause the composition/mixture to be too viscous to be processed, for example by pumps and machinery.

The first and the second compositions described herein may be mixed to provide a mixture of the first composition and the second composition. The mixture of the first composition and the second composition may be formed by homogenising the first composition and the second composition. The mixture of the first composition and the second composition maybe in the form of a “dough”.

In some embodiments, the mixture is extruded to form the aerosol generating composition, prior to being impressed with indentations. For example, the aerosol generating composition may be extruded into the form of a sheet and then feed into rollers to impress indentations on to the first and/or second surface of the sheet, producing the aerosol generating material as described.

Extrusion involves the feeding of the aerosol generating composition through an orifice to produce an extruded agglomerate. The process, which applies pressure to the precursor composition combined with shear forces, results in agglomerated structures, which may be in the form of a sheet.

Extrusion may be performed using one of the main classes of extruders: screw, sieve and basket, roll, ram and pin barrel extruders. Forming the sheet structures by extrusion has the advantage that this processing combines mixing, conditioning, homogenizing and moulding of the mixture of the first composition and the second composition.

In some embodiments, the method of manufacturing the aerosol-generating material comprises a casting (e.g. band casting) or paper making process.

Other materials may also be added during the extrusion process, such as a base, diluent, solid aerosol forming agents, solid flavour modifiers, expansion agents and other additives known in the art. This has the advantage that the additive is evenly distributed throughout the agglomerated structures formed.

In some embodiments, the aerosol generating composition is extruded and impressed with indentations at the same time. This provides the advantages that this is faster and reduces the apparatus required. In some embodiments, the aerosol generating material may be dried. Any suitable apparatus may be used, using air, infrared or microwaves for example.

In some embodiments, the aerosol generating material may be gathered. This is a process wherein the material is passed through a conical or funnel device to gather the material together.

In some embodiments, the aerosol generating material is cut or sliced to truncate its length.

In some embodiments, the aerosol generating material may have a length of up to about 34 mm. In some embodiments, the aerosol generating material may have a length of up to about 34, about 24, about 20, about 16 about 12 or about 10 mm. In some embodiments, the aerosol generating material may have a length of at least about 34, about 24, about 20, about 16 about 12 or about 10 mm. The length may be selected to fit the article and to provide a suitable flavour delivery to the user.

In some embodiments, the aerosol generating material may have a width of up to about 2 mm. In some embodiments, the aerosol generating material may have a width of up to about 2 mm, up to about 1.4 mm, or up to about 1 mm. In such embodiments, the aerosol generating material maybe form of a sheet, shredded sheet, strand and/or strip. As used herein, the term “width of the aerosol generating material” denotes a dimension in a direction transverse to the length. Aerosol generating materials with smaller widths are associated with being easier to break, and thus aerosol generating materials with larger widths are stronger. This may also have a negative effect on the consistency of the pressure drop across the material. On the other hand, the material must be a suitable width to fit into the article and be suitable for handling. It has also been noted that when the aerosol generating material has a larger width, the shape of the indentations may be distorted, for example may be less round or circular.

The width of the aerosol generating material may be selected to align with the pattern of the indentations, so that the indentions may be optimally located on the material.

The width of the of the aerosol generating material may be selected to be suitable with the width and/or height of the indentions. Thus, the width of the of the aerosol generating material may be selected to be suitable with the number of the indentions per cm3. In some embodiments, the method to make the aerosol generating material includes the steps of combining the steps of extrusion, drying, gathering and/or cutting.

Figure 7 illustrates how the aerosol generating material may be manufactured. A first composition comprising a binder and an aerosol former and a second composition comprising botanical material, filler and optionally a second binder are formed and mixed. In the subsequent step the first composition and the second composition are mixed and extruded to form a sheet of aerosol-generating material. Following this, the extruded mixture of the first composition and the second composition may be impressed with indentations and optionally dried. The sheet may then be cut and may then be incorporated into an article for a non-combustible aerosol deliveiy system.

In some embodiments, the aerosol generating material is impressed just before the optional cutting step. This provides the advantage of there is minimal deformation of the indentations. For example, the impressing step is at a late stage of the production process of the aerosol generating material and so the material requires little further processing after the indentations are formed.

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.

Claims

Claims i. An aerosol generating material comprising a first surface and a second surface and indentations on the first surface and/or the second surface.

2. An aerosol generating material comprising one or more elongate strips, wherein each strip comprises a first surface and a second surface and indentations on the first surface and/or the second surface.

3. An aerosol generating material comprising a sheet, wherein the sheet comprises a first surface and a second surface and indentations on the first surface and/or the second surface.

4. The aerosol generating material according to any preceding claim, wherein the indentations have the shape selected from a group consisting of: circular, semi-circular, crescent, square, triangle, Y-shape, lines, rectangle, cone or star.

5. The aerosol generating material according to any preceding claim, wherein the indentations comprise a length and a width and an average width of the indentations of about o.oi to about 5 mm.

6. The aerosol generating material according to any preceding claim, wherein the indentations have a length and a width, and wherein the length and the width have a ratio of about 1:0.25 to about 1:10.

7. The aerosol generating material according to claim 5 or 6, wherein the length of the aerosol generating material is at most about 34 mm.

8. The aerosol generating material according to any preceding claim, wherein each of the indentations have a volume of about 0.00001 to about 10 mm3.

9. The aerosol generating material according to any preceding claim, wherein the average volume density of the aerosol generating material is from about 0.4 g/cm3 to about 1 g/cm3.

10. The aerosol generating material according to any preceding claim, wherein the aerosol generating material comprises about 100 to about 500 indentations per cm².

11. The aerosol generating material according to any preceding claim, wherein the thickness of the aerosol generating material is from about 100 pm to 350 pm.

12. The aerosol generating material according to any preceding claim, wherein the thickness of the aerosol generating material increases by about 10 to 40%, compared to an equivalent material without the indentations.

13. The aerosol generating material according to any preceding claim, wherein the aerosol generating material has a tensile strength of at least 3 N/ismm.

14. The aerosol generating material according to any preceding claim, wherein the aerosol generating material comprises water, optionally wherein the aerosol water content is up to about 15% by weight of the aerosol generating material.

15. The aerosol generating material according to any preceding claim, wherein the aerosol generating material comprises botanical material.

16. The aerosol generating material according to claim 15, wherein the aerosol generating material comprises a botanical material content of from about 50 to about 80% by weight of the aerosol generating material.

17. The aerosol generating material according to any preceding claim, wherein the aerosol generating material comprises at least one binder.

18. The aerosol generating material according to claim 17, wherein the aerosol generating material comprises a binder content of from 5 to about 40% by weight of the aerosol generating material.

19. The aerosol generating material according to any preceding claim, wherein the aerosol generating material is in a form selected from a group consisting of: sheet, shredded sheet, gathered sheet, rod or strand.

20. An article for use in a non-combustible aerosol-provision system comprising an aerosol-generating section comprising the aerosol generating material according to any preceding claim.

21. The article according to claim 20, wherein the article has a pressure drop between an upstream end and a downstream end of the article from about 40 to about 120 mmWg.

22. The article according to either claim 20 or claim 21, wherein the article comprises an aerosol-generating section and a pressure drop across the aerosolgenerating section is from 50 to about 500 mmWg.

23. A method of producing the aerosol generating material according to any one of claims 1 to 19, wherein the method comprises forming an aerosol-generating material composition, impressing recesses into a surface of the aerosol generating composition to form indentations in the surface and drying the aerosol generating composition to form the aerosol-generating material comprising the indentations.

24. A method according to claim 23, wherein the aerosol generating material is prepared by extruding an aerosol generating composition.

25. An aerosol-generating material produced by the method according to either claim 23 or claim 24.