JP2023547347A - Aerosol generating materials - Google Patents

Abstract

Disclosed herein are the steps of forming a first composition comprising a first binder and an aerosol forming material; a second composition comprising a tobacco material, a filler, and optionally a second binder; forming a composition; combining the first composition and the second composition to form a mixture of the first composition and the second composition; a binder, a second binder, and a filler in a total amount between about 5% and about 15% by weight of the mixture; A method for preparing an aerosol-generating material comprising processing to form an aerosol-generating material. [Selection diagram] None

Description

The present disclosure relates to aerosol-generating materials, methods of making aerosol-generating materials, and articles comprising aerosol-generating materials.

background

Certain tobacco industry products generate aerosols that are inhaled by the user during use. For example, tobacco heating devices heat an aerosol-generating material, such as tobacco, to form an aerosol by heating the substrate without burning it. Such tobacco industry products generally include a mouthpiece through which the aerosol reaches the user's mouth.

overview

According to a first aspect of the invention, forming a first composition comprising a first binder and an aerosol-forming agent; a second composition comprising a tobacco material, a filler, and optionally a second binder; combining the first composition and the second composition to form a mixture of the first composition and the second composition; a binder, a second binder, and a filler in a total amount between about 5% and about 15% by weight of the mixture; and a mixture of the first composition and the second composition. A method for preparing an aerosol-generating material is provided, comprising processing an aerosol-generating material to form an aerosol-generating material.

According to a second aspect of the invention there is provided an aerosol-generating material prepared by the method according to the first aspect.

According to a third aspect of the invention there is provided an article for use in a non-flammable aerosol delivery system comprising an aerosol-generating material according to the second aspect.

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

FIG. 2 illustrates steps of a method used to produce an aerosol-generating material. 1 is a side cross-sectional view of an article comprising an aerosol-generating material. FIG. 3 is a perspective view of a non-flammable aerosol delivery device for generating an aerosol from the aerosol-generating material of the article of FIG. 2; FIG. 1 is a graph showing changes in nicotine and glycerol levels in a mixture of a first composition and a second composition and in an aerosol-generating material.

detailed description

The present invention provides the steps of forming a first composition comprising a first binder and an aerosol-forming agent; forming a second composition comprising a tobacco material, a filler, and optionally a second binder. combining the first composition and the second composition to form a mixture of the first composition and the second composition, the mixture comprising a first binder, an optional binder; a second binder and a filler in a total amount between about 5% and about 15% by weight of the mixture; and processing the mixture of the first composition and the second composition. , relates to a method for preparing an aerosol-generating material, the method comprising forming an aerosol-generating material.

An aerosol-generating material is, for example, a material that can generate an aerosol when heated, irradiated, or otherwise energized. The aerosol-generating material may be in solid, liquid, or gel form and may or may not contain active substances and/or flavorants. Aerosol-generating materials can be incorporated into articles for use in aerosol-generating systems.

According to one aspect of the present disclosure, an aerosol-generating material is provided. The aerosol-generating material is arranged to generate an aerosol upon heating.

The moisture content of the aerosol-generating materials described herein can vary depending on, for example, the temperature, pressure, and humidity conditions under which the composition is maintained. Moisture content can be determined by Karl Fischer analysis, as is known to those skilled in the art.

Unless otherwise specified, as used herein, the terms "volatile components", "volatiles", "total volatiles", "volatiles content" and "total volatiles" refer to used to refer to volatile compounds containing The volatile content of the material can be determined as the mass lost when the sample is dried for 3 hours ± 0.5 minutes in a forced draft oven at a temperature adjusted to 110°C ± 1°C. After drying, the sample is cooled to room temperature in a desiccator for about 30 minutes to cool the sample.

FIG. 1 shows how an aerosol-generating material can be manufactured. A first composition comprising a binder and an aerosol former and a second composition comprising a tobacco material, filler and optionally a second binder are formed and mixed. In a subsequent step, the first and second compositions are mixed and extruded. Following this, the extrusion mixture of the first composition and the second composition may be dried to form a sheet of aerosol-generating material. The sheet may then be shredded to create an aerosol-generating material, which may then be incorporated into consumables for non-flammable aerosol delivery systems.

The first composition, also known as the "wetting mix", includes an aerosol former or humectant and a binder. The first composition may also include other liquids or suspensions disclosed herein. The first composition may be in liquid phase.

The first composition includes an aerosol former. Aerosol-forming materials include one or more components capable of forming an aerosol. Aerosol forming materials include glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, Containing one or more of triacetin, diacetin mixture, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In some embodiments, the aerosol former is glycerin, glycerol or propylene glycol.

The first composition includes a first binder. The binder is arranged to bind the components of the first composition. When combined with the second composition, the binder binds the components of the first and second compositions to form an aerosol-generating material. The first composition may include more than one binder. In such embodiments, the binders in the first composition may be the same or different.

The binder is one or more compounds selected from the group including alginates, pectins, starches (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clays, polyvinyl alcohols and combinations thereof. May be selected. For example, in some embodiments, the binder is alginate, pectin, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose (CMC), pullulan, xanthan gum, guar gum, carrageenan, agarose, gum acacia, fumed silica, PDMS, Contains one or more of sodium silicate, kaolin and polyvinyl alcohol. Optionally, the binder includes alginate and/or pectin or carrageenan. In some embodiments, the binding agent comprises CMC.

The second composition, also known as a "dry mix," includes tobacco material, filler, and optionally a second binder. The second composition may include other solids or gels disclosed herein. The second composition may be in solid phase.

As used herein, the term "tobacco material" refers to any material that includes tobacco or a derivative or substitute 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, regenerated tobacco, regenerated paper tobacco, or tobacco substitutes. The tobacco material may include one or more of ground tobacco, tobacco fiber, shredded tobacco, extruded tobacco, tobacco stems, tobacco lamina, recycled tobacco, and/or tobacco extract.

The tobacco material may be particulate or granular material. In some embodiments, the tobacco material may be powdered or ground. Alternatively, or in addition, the tobacco material may include tobacco strips, strands or fibers. For example, the tobacco material may include tobacco particles, granules, fibers, strips and/or strands. In some embodiments, the tobacco material consists of particles or granules of tobacco material. In some embodiments, the tobacco material is in particulate or ground form, which is similar to the dough material formed upon combining the first and second compositions. This is to assist in formation.

In embodiments where the tobacco is particulate tobacco material, each particle of the particulate tobacco material may have a maximum dimension. As used herein, the term "maximum dimension" means the longest dimension on the surface of a tobacco particle, or from any point on the particle surface to any other surface point on the same tobacco particle or particle surface. Refers to straight line distance. The maximum particle size of particulate tobacco material can be measured using scanning electron microscopy (SEM).

In some embodiments, the largest dimension of each particle of tobacco material ranges from about 800 μm. In some embodiments, the largest dimension of each particle of tobacco material ranges from about 2000 μm. In some embodiments, the largest dimension of each particle of tobacco material is about 200 μm to about 800 μm.

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

The inventors have discovered that the particle size distribution (D90) of tobacco materials can be controlled to achieve desired areal density in aerosol-generating materials and sheets, shredded sheets or products made from the materials. Ta. The areal density of a material can be measured in GSM (grams per square meter, g/m ² ). For example, a smaller particle size distribution (D90) is associated with a larger areal density. This high areal density may reduce the loading value of the tobacco material when the aerosol-generating material is incorporated into an article for use in a non-flammable aerosol delivery system. A particular example of this is that a particle size distribution (D90) of 300 is predicted to yield an areal density of 246.6 g/ ^m2 .

The inventors also note that lower areal density is also associated with better taste and organoleptic properties of aerosol-generating materials and sheets, shredded sheets or products made from the materials. Because the method for producing aerosol-generating materials produced by the methods of the present disclosure involves less drying than conventional methods, fewer volatile components (many of which are considered desirable) are lost. Less volatile components lost is associated with better organoleptic properties, as taste and aroma are better retained. Additionally, the method requires less energy to remove volatile compounds.

However, the areal density should not be too low, as this reduces the amount of tobacco in the material that the consumer perceives as providing positive organoleptic properties, reducing the organoleptic properties. Additionally, since materials with higher areal density may contain more tobacco material, lowering the areal density can reduce the amount of tobacco material required, providing additional economic benefits.

The inventors have discovered that the particle size distribution (D90) can be controlled to achieve desired tensile strength in aerosol-generating materials and sheets, shredded sheets or products made from the materials. For example, a larger particle size distribution (D90) is associated with lower tensile strength. Without wishing to be bound by reason, the larger the particle size distribution, the less material is bonded together. This may cause the aerosol-generating material, and the sheets, shredded sheets or products produced therefrom, to be weaker and therefore have less tensile strength. A particular example of this is that a particle size distribution (D90) of 269.2 is predicted to yield a tensile strength of 7.4 N/15 mm.

The inventors have determined that there is an optimum balance between areal density and tensile strength of the aerosol-generating material and the sheet, shredded sheet or product made from the material, and that this balance is achieved by the selection of the particle size distribution (D90). I found out what can be achieved by The particle size distribution (D90) needs to be small enough to provide adequate tensile strength, but large enough to provide areal density that provides positive organoleptic properties to the user and facilitates removal of volatile compounds. It is.

For example, the particle size distribution (D90) can be selected to yield a sufficiently low areal density to provide positive organoleptic properties, but a sufficiently high tensile strength to be within the operating limits of the manufacturing machinery. A particle size distribution (D90) of at least about 100 μm is believed to contribute to the tensile strength of the aerosol-generating material. The inventors have found that a particle size distribution (D90) of less than 100 μm provides an aerosol-generating material with good tensile strength. However, when the aerosol-generating material includes fine particles of such tobacco material, the density of the aerosol-generating material can increase. This greater density may reduce the fill value of the tobacco material when the aerosol-generating material is incorporated into an article for use in a non-flammable aerosol delivery system. Advantageously, the inventors have found that a balance between sufficient tensile strength and suitable areal density (and thus filling value) can be achieved if the particle size distribution (D90) is at least 100 μm. Ta. In some embodiments, the particle size distribution (D90) is 100-800 μm.

In some embodiments, the particle size distribution (D90) is 160-450 μm. In some embodiments, the particle size distribution (D90) is 200-450 μm.

A particle size distribution (D90) of at least about 180 μm is believed to contribute to suitable tensile strength of the aerosol-generating material. The inventors have found that a particle size distribution (D90) of at least about 200 μm provides an aerosol-generating material with good tensile strength. The inclusion of finer particles of tobacco material in the aerosol-generating material can increase its areal density. Selection of the particle size distribution (D90) can result in suitable tensile strength and areal density of the aerosol-generating material, which is the same or improved over aerosol-generating materials produced with "band casting" techniques. As mentioned in Example 3, compared to aerosol-generating materials made by band casting methods, aerosol-generating materials made by the method of the present invention have a larger surface area while maintaining adequate tensile strength. It can be seen that it has density and density.

The second composition includes a filler. Fillers are generally non-tobacco ingredients, ie, ingredients that do not contain materials or ingredients derived from tobacco. The filler may include one or more inorganic filler materials such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents such as molecular sieves. . The filler may be non-tobacco fibers such as wood fibers or pulp or wheat fibers. The filler may be a material containing cellulose or a material containing a derivative of cellulose. The filler component may also be a non-tobacco cast or extruded material. In some embodiments, the filler is a cellulosic material, cellulose or CMC. In some embodiments, the filler consists essentially of or consists of cellulose.

In certain embodiments that include fillers, the fillers are fibrous. For example, the filler may be a fibrous organic filler material such as wood, wood pulp, hemp fibers, cellulose or cellulose derivatives. Without wishing to be bound by theory, it is believed that the inclusion of fibrous fillers can increase the tensile strength of the aerosol-generating material formed. The use of cellulose as a filler has been found to have a particularly favorable impact on the burst strength of aerosol-generating materials.

Fillers may also contribute to the texture of the aerosol-generating material. For example, a fibrous filler such as cellulose can provide an aerosol-generating material with relatively rough first and second surfaces. Conversely, non-fibrous particulate fillers, such as powdered chalk, can provide an aerosol-generating material with relatively smooth first and second surfaces. In some embodiments, the aerosol-generating material includes a combination of different filler materials. Fillers may help improve the general structural properties of the aerosol-generating material, such as tensile strength and burst strength.

Incorporating a relatively large amount of the first binder into the first composition relative to the aerosol forming agent results in a highly viscous mixture, such that the first composition is blended with the second composition. It may become difficult. We reduced the amount of the first binder in the first composition and added a second binder (which may be the same as the first binder or different) to the second composition. It has been found that this problem can be solved by adding the following:

Accordingly, the second composition may include an optional second binder. In some embodiments of the invention, the first binding agent and the second binding agent are the same. In some embodiments of the invention, the first binding agent and the second binding agent are different. The binder is one or more compounds selected from the group including alginates, pectins, starches (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clays, polyvinyl alcohols and combinations thereof. May be selected. For example, in some embodiments, the binder is alginate, pectin, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose (CMC), pullulan, xanthan gum, guar gum, carrageenan, agarose, gum acacia, fumed silica, PDMS, Contains one or more of sodium silicate, kaolin and polyvinyl alcohol. Optionally, the binder includes alginate and/or pectin or carrageenan. In some embodiments, the binding agent comprises CMC.

As mentioned above, by incorporating a second binder into the second composition, the amount of the first binder in the first composition can be reduced, thus reducing the amount of the first binder in the first composition. The viscosity of the composition decreases, making it easier to form a mixture of the first composition and the second composition. The binder may at least partially coat the surface of the tobacco material. When the tobacco material is in particulate form, the binder may at least partially coat the surface of the tobacco particles and bind the particles together.

The total volatile content of the second composition may be about 10-15% by weight of the second composition. The total volatile content may be about 5%, 10%, 15%, 20%, 25%, 30%, 35% or 40% by weight of the second composition. .

A first composition and a second composition described herein may be mixed to provide a mixture of the first composition and the second composition. A mixture of the first composition and the second composition may be formed by homogenizing the first composition and the second composition. The mixture of the first composition and the second composition may be in the form of a "dough." Advantageously, it is necessary to add minimal or no water to the mixture in order to provide a homogeneous dough suitable for subsequent processing steps. For example, the dough may then be extruded through a die, preferably with the addition of no further water or even a homogeneous dough with a small amount of water being passed through the die. good.

We combined the first binder, aerosol-generating material, tobacco material, filler, and optional second binder in a single step (i.e., the first composition and the second composition separately). It has been found that mixing (without forming a mixture and then combining them) can result in a viscous mixture that is difficult to process and handle. By forming the first composition and the second composition separately and then combining these compositions, the resulting "dough" mixture can be more easily processed.

The tobacco material may be present in an amount from about 50% to about 80% by weight of the mixture of the first composition and the second composition. For example, the tobacco material may be present in an amount of about 50%, 60%, 70%, 80%, or 90% by weight of the mixture of the first composition and the second composition. . In some embodiments, the tobacco material is present in an amount of about 75% by weight of the mixture of the first composition and the second composition.

The filler component may be present in an amount of 0 to 20% by weight of the mixture of the first composition and the second composition, or in an amount of 1 to 10% by weight of the mixture of the first composition and the second composition. May be present in amounts. For example, the filler may be about 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8% by weight of the mixture of the first composition and the second composition. It may be present in amounts greater than 9%, 9% or 10% by weight. In some embodiments, the filler component is present in an amount of 5% by weight of the mixture of the first composition and the second composition, which by including 5% of the filler This is because the inventors have discovered that the bursting strength of is improved and the brittleness is reduced.

The aerosol-forming agent is present in an amount of about 10% to about 25% by weight of the mixture of the first composition and the second composition, or 1% of the mixture of the first composition and the second composition. It may be present in an amount of up to about 10% by weight. For example, the aerosol-forming agent is present in an amount of about 10%, 12%, 15%, 18%, 20%, or 25% by weight of the mixture of the first composition and the second composition. May exist. In some embodiments, the aerosol former is present in an amount of about 15% by weight of the mixture of the first composition and the second composition.

The binder is present in an amount of about 1% to about 20% by weight of the mixture of the first composition and the second composition, or 1% to about 10% by weight of the mixture of the first composition and the second composition. May be present in amounts of % by weight. For example, the binder is about 1%, 2%, 3%, 4%, 5%, 6%, 7%, by weight of the mixture of the first composition and the second composition. It may be present in amounts greater than 8%, 9% or 10% by weight. In some embodiments, the binder is present in an amount greater than about 2% by weight of the mixture of the first composition and the second composition. In some embodiments, the binder is present in an amount of about 5%, or up to about 5% by weight of the mixture of the first composition and the second composition. The amount of binder in the first composition, the second composition, and the mixture of the first and second compositions is important because it changes the consistency of the compositions and mixtures. be. If the amount of binder is too high, the viscosity of the composition/mixture may become too high to be processed in pumps and machines, for example.

In embodiments of the invention where a first and a second binder are provided, the ratio of the first binder to the second binder may be between 1:1 and 1:10. . This ratio is advantageously selected to maintain the physical properties of the sheet and provide adequate bonding of the mixture and/or aerosol-generating material without degrading the texture of the composition. The ratio of the first binder to the second binder is about 1:10, 2:8, 3:7, 4:6, 5:5, 10:1, 8:2, 7:3, respectively. The ratio may be 6:4. In some embodiments, the ratio of the first binder to the second binder to maintain the physical properties of the sheet or shredded sheet is 4:6, respectively. If the first composition contains all the binder, the viscosity of the first composition may become too high to be processed, for example, by pumps and machines. Providing a binder to both the first composition and the second composition facilitates processing of the composition.

We include the first binder, optional second binder, and filler in a total amount of about 5% to about 15% by weight of the mixture of the first composition and the second composition. It has been unexpectedly discovered that incorporation of 100% by 20% has a beneficial effect on the burst strength, strength, and flexibility of aerosol-generating materials. The mixture of the first composition and the second composition comprises, in total, about 2%, about 5%, about 8%, on a dry weight basis, of the first binder, the optional second binder, and the filler. %, about 10%, about 12% or about 15%. In some embodiments, the mixture of the first composition and the second composition includes 5% first binder, optional second binder, and 5% filler. Incorporation of the first binder, optional second binder, and filler in this manner can reduce stickiness, increase burst strength, and improve flexibility of the aerosol-generating material.

In certain embodiments, the first binder and the optional second binder are both CMC, the total amount of binder is 5%, the filler is cellulose, and the total amount of cellulose is 5%. . Accordingly, in such embodiments, the mixture of the first composition and the second composition comprises 5% CMC and 5% cellulose. The inventors have found that the presence of these amounts of binder and filler has a particularly beneficial effect on the physical properties of the aerosol-generating material, including improved strength and flexibility. Cellulose fillers improve the burst strength and reduce brittleness of aerosol-generating materials.

The aerosol-generating material may have a burst strength of at least about 75 g, at least about 100 g, or at least about 200 g. In some embodiments, the aerosol generating material may have a burst strength of at least 150 g.

If the burst strength is too low, the aerosol-generating material may become relatively brittle. As discussed herein, aerosol-generating materials may be formed into sheets or shredded sheets. As a result, breakage of the sheet or shredded sheet may occur during the manufacturing process of the aerosol-generating material. For example, if the cutting process shreds the sheet to form a shredded sheet, the sheet may shatter or break into pieces during cutting. Incorporation of a first binder, an optional second binder, and a filler may help improve the general structural properties of the aerosol-generating material, such as tensile strength and burst strength.

The volatile content in the mixture of the first composition and the second composition may be greater than 20% by weight of the mixture of the first composition and the second composition. The volatile content is from about 5%, 10%, 15%, 20%, 25%, 30%, 40% by weight of the mixture of the first composition and the second composition. It may be more. In some embodiments, about 20 to about 30% water is added to the mixture of the first composition and the second composition. In some embodiments, about 26% water is added.

The total volatile content of the mixture of the first composition and the second composition may be about 22-29% by weight. The total volatile content is about 5%, 10%, 15%, 20%, 25%, 30%, 40% by weight of the mixture of the first composition and the second composition. It may be.

The amount of water in the mixture of the first composition and the second composition may be greater than 20% by weight of the mixture of the first composition and the second composition. The amount of water is greater than about 5%, 10%, 15%, 20%, 25%, 30%, 40% by weight of the mixture of the first composition and the second composition. Good too. In some embodiments, about 20 to about 30% water is added to the mixture of the first composition and the second composition. In some embodiments, about 26% water is added.

The total water content of the mixture of the first composition and the second composition may be about 22-29% by weight. The total water content is about 5%, 10%, 15%, 20%, 25%, 30%, 40% by weight of the mixture of the first composition and the second composition. It's okay.

The present invention enjoys the additional advantage that less water is required than other conventional compositions to create a doughy mixture of the first and second compositions. Because of this, the mixture of the first composition and the second composition can be easily mixed without the need for adding additional water or agents to form a homogeneous mixture suitable for extrusion. It has the advantage that it can be mixed. An additional benefit of requiring less water is that it increases the reliability of the manufacturing process. As a result, the manufacturing process is also repeatable, which also has cost-reducing implications. Therefore, the total water content of the mixture of the first composition and the second composition is relatively low.

As a result of this lower water content, less water needs to be removed during the processing step. For example, a "band casting" process uses a slurry with a target moisture content of about 75% to about 80%. This slurry then needs to be dried to a target moisture content of about 13%, thus requiring a water reduction of about 67%. In the invention disclosed herein, the mixture of the first composition and the second composition incorporates minimal water. For example, the resulting dough may lose only about 16% water in the final product. Accordingly, compared to methods of forming aerosol-generating materials that include slurries, such as band casting processes, the methods described herein may result in about 50% or about 60% less water loss. . Advantageously, less water needs to be removed during the processing stage and therefore less energy is consumed. Less energy consumed is greener, faster and more cost-effective. Additionally, because less drying is required, taste and aroma are better retained.

Aerosol-generating materials produced by the methods disclosed herein have volatile content between about 5% and about 15%. This allows the aerosol-generating material to be cut into strips with relative ease. If the volatile content, especially the moisture content, is too high, the aerosol-generating material may tear during the cutting process, which is undesirable. If the volatile content is too low, it may be too brittle and shatter during the cutting process.

The present invention enjoys the additional advantage that lower amounts of certain volatile components, particularly nicotine and glycerol, are lost during drying of the mixture of the first and second compositions. Without wishing to be bound by reason, the mixture of the first composition and the second composition contains a relatively lower amount of water and therefore requires less drying than slurries known to those skilled in the art. Less is. For example, lower temperatures and shorter drying times may be utilized to achieve the desired volatile content of the aerosol-generating material. This also reduces the loss of certain valuable volatile components and improves the flavor, taste and mouthfeel characteristics of the aerosol produced in the final product.

In an exemplary embodiment, the mixture of the first composition and the second composition comprises about 75% tobacco material (tobacco), about 15% aerosol former (glycerin), about 5% filler (cellulose), binder (CMC, about 2% in the first composition and about 3% in the second composition). In this embodiment, the composition does not include guar gum. The inventors have discovered that a mixture of a first composition and a second composition provides the advantages disclosed herein.

Once formed and mixed, the mixture of the first and second compositions can be extruded to form an aerosol-generating material using any extrusion technique or equipment known in the art. can be formed.

Extrusion involves feeding a precursor composition through an orifice to produce an extruded mass. The process of applying pressure to the precursor composition and combining shear forces results in a cohesive structure that may be in the form of a sheet.

Extrusion can be carried out using one of the major classes of extruders: screw, sieve and basket, roll, ram, and pin barrel extruders. Forming the sheet structure by extrusion has the advantage that this processing also combines mixing, conditioning, homogenizing and shaping the mixture of the first and second compositions.

Other materials such as bases, diluents, solid aerosol formers, solid flavor modifiers, swelling agents and other additives known in the art can also be added during the extrusion process. Addition during the extrusion process has the advantage that the additive is uniformly distributed throughout the agglomerated structure that is formed.

The resulting extrusion mixture of the first composition and the second composition can be dried using any suitable drying technique known in the art. For example, microwave drying, infrared drying, air drying, and oven drying are suitable techniques for drying aerosol-generating materials. The temperature of the drying step may be less than 100°C, and in some embodiments of the invention less than 90°C. The drying temperature utilized may be up to about 25°C, about 30°C, about 40°C, about 50°C, about 60°C, about 70°C, about 80°C, about 90°C, or about 100°C. .

The resulting extrusion mixture of the first composition and the second composition may be processed by forming a layer of the mixture on the surface and then drying the mixture to remove at least a portion of the water. It may be removed to form a sheet of aerosol-generating material.

Water can be removed by evaporating it from the extrusion mixture at ambient temperature and pressure (eg, 25° C. and 101 kPa). Alternatively, applying heat to the extrusion mixture (e.g., heating it above about 25°C) and/or increasing the atmospheric pressure surrounding the extrusion mixture of the first composition and the second composition (e.g., to less than 101 kPa). ) Water may be removed by lowering.

The lower drying temperatures utilized are advantageous because they reduce the amount of volatile components such as nicotine, glycerol and flavorings that are lost, which contribute to the flavor, taste and mouthfeel of the final product. In some embodiments of the invention, the amount of nicotine and glycerol lost is less than about 10%, less than about 8%, less than about 5%, less than about 4%, less than about 2%, or less than about 1% in total. It is. In some embodiments, the total amount of volatiles lost is less than 5%. In some embodiments of the invention, the amount of glycerol and nicotine lost in total is less than about 10%, less than about 8%, less than about 5%, less than about 4%, less than about 2%, or less than about 1%. It is. In some embodiments, the amount of glycerol and nicotine lost is less than 5% in total. Accordingly, the aerosol-generating material has a total volatile content that is less than the mixture of the first composition and the second composition.

The aerosol-generating material may include total volatiles in an amount less than about 20%, less than about 15%, less than about 10%, or less than about 5% of the aerosol-generating material. In some embodiments, the aerosol-generating material comprises total volatiles in an amount between about 0% and about 15%, or between about 5% and about 15%, by weight of the aerosol-generating material. . In some embodiments, the aerosol generating material may have a total volatile content of about 9-13% by weight.

The aerosol generating material may include water. The aerosol-generating material may include water in an amount less than about 20%, less than about 15%, less than about 10%, or less than about 5% of the aerosol-generating material. In some embodiments, the aerosol-generating material includes water in an amount between about 0% and about 15%, or between about 5% and about 15%, by weight of the aerosol-generating material. In some embodiments, the aerosol-generating material includes water in an amount between about 5% and about 15% by weight of the aerosol-generating material. Therefore, the aerosol-generating material has a lower moisture content than the mixture of the first composition and the second composition.

In some embodiments, the amount of water lost from the mixture of the first and second compositions and the aerosol-generating material is between 10-50%. In some embodiments of the invention, the amount of water lost is about 10%, about 15%, about 25%, about 30%, about 40% or about 50%. In some embodiments, the amount of water lost is about 26%.

The sheet or shredded sheet of aerosol-generating material may include water and an aerosol-forming agent in a total amount of less than about 30% by weight of the sheet or shredded sheet of aerosol-generating material, or less than about 25% by weight of the aerosol-generating material. . By incorporating water and an aerosol-forming agent into the sheet or shredded sheet of aerosol-generating material in an amount less than about 30% by weight of the sheet or shredded sheet of aerosol-generating material, the tackiness of the sheet may be advantageously reduced. It seems possible. This makes it easier to handle the aerosol-generating material during processing. For example, it may be easier to roll a sheet of aerosol-generating material to form a bobbin of material and then unroll the bobbin without the layers of the sheet sticking together. Reducing tackiness also reduces the tendency of shredded material strands or strips to clump or stick together, further improving processing efficiency and final product quality.

After drying, the sheet of aerosol-generating material may be cut into strips or strands of aerosol-generating material. A sheet of aerosol-generating material of uniform thickness can be fed to the shredding device. This can be achieved, for example, by providing a bobbin of sheet material that can be continuously fed to the shredding device. Alternatively, separate portions of sheet-like aerosol-generating material, such as sheets known to those skilled in the art as flags, can be fed to a shredding device. Strips or strands of aerosol-generating material can be assembled and formed into articles for use in non-flammable aerosol delivery systems. Optionally, the aerosol-generating material can be crimped before being collected and formed into an article. Optionally, the aerosol-generating material may be subjected to a second cutting step, such as a cross-cut shredding process, to obtain a defined cutting length.

The first and/or second surfaces of the sheet or shredded sheet may be relatively uniform (eg, relatively smooth), non-uniform or irregular. For example, the first and/or second surfaces of the sheet may be textured or patterned to define a relatively rough surface. In some embodiments, the first and/or second surfaces are relatively rough.

The smoothness of the first and second surfaces may depend on the areal density of the sheet or shredded sheet, the nature of the components making up the aerosol-generating material, or whether the surface of the material is patterned, for example by being embossed, scored or otherwise patterned. It may be affected by many factors, such as whether or not it has been processed to add texture.

The sheet or shredded sheet of aerosol-generating material has a thickness of at least about 100 μm. The sheet or shredded sheet may have a thickness of at least about 100 μm, 120 μm, 140 μm, 160 μm, 180 μm, 200 μm, 220 μm, 240 μm, 260 μm, 280 μm, 290 μm, or 300 μm. In some embodiments, the sheet or shredded sheet is about 100 μm to about 300 μm, about 151 μm to about 299 μm, about 152 μm to about 298 μm, about 153 μm to about 297 μm, about 154 μm to about 296 μm, about 155 μm to about 295 μm, It has a thickness of about 156 μm to about 294 μm, about 157 μm to about 293 μm, about 158 μm to about 292 μm, about 159 μm to about 291 μm, or about 160 μm to about 290 μm. In some embodiments, the sheet or shredded sheet has a thickness of about 170 μm to about 280 μm, about 180 to about 270 μm, about 190 to about 260 μm, about 200 μm to about 250 μm, or about 210 μm to about 240 μm. In some embodiments, the thickness of the sheet or shredded sheet is about 200 μm.

The thickness of the sheet or shredded sheet may differ between the first and second surfaces. In some embodiments, each strip or piece of aerosol-generating material has a minimum thickness over its area of about 100 μm. In some cases, each strip or piece of the sheet or shredded sheet of aerosol-generating material has a minimum thickness over its area of about 0.05 mm or about 0.1 mm. In some cases, each strip, strand, or piece of the sheet or shredded sheet of aerosol-generating material has a maximum thickness over its area of about 1.0 mm. In some cases, each strip or piece of aerosol-generating material has a maximum thickness over its area of about 0.5 mm or about 0.3 mm.

ISO 534:2011 "Paper and Board-Determination of Thickness" can be used to determine the thickness of the sheet.

The inventors have determined that if the sheet or shredded sheet of aerosol-generating material is too thick, heating efficiency can be compromised. This can have a negative impact on power consumption during use, for example to release flavor from the aerosol generating material. Conversely, if the sheet or shredded sheet of aerosol-generating material is too thin, it may be difficult to manufacture and handle. Very thin materials can be difficult to cast, are fragile, and may compromise aerosol formation during use.

If the sheet of aerosol-generating material or shredded sheet is too thin (e.g., less than 100 μm), the shredded sheet must be It is assumed that there may be cases where it is necessary to increase the cutting width. Increasing the cutting width of the shredded sheet can increase pressure loss, which is undesirable.

Aerosol-generating materials having a thickness of at least about 100 μm and an areal density of about 100 g/m ² to about 240 or 250 g/m ² are susceptible to tearing, tearing, or other deformation during manufacturing. expected to be low. Additionally, aerosol-generating materials having areal densities of about 100 g/m ² to about 240 or 250 g/m ² are less likely to tear, tear, or otherwise deform during manufacturing. A thickness of at least about 100 μm can positively impact the overall structural integrity and strength of the sheet or shredded sheet. For example, sheets or shredded sheets of such thickness may have good tensile strength and therefore be relatively easy to process. In some embodiments, the areal density is between about 170 and about 240 or 250 g/m ² . In some embodiments, the areal density is about 180 g/ ^m2 .

It is also believed that the thickness of a sheet or shredded sheet is related to its areal density. That is, by increasing the thickness of the sheet or shredded sheet, the areal density of the sheet or shredded sheet can be increased.

Conversely, reducing the thickness of the sheet or shredded sheet may reduce the areal density of the sheet or shredded sheet. For the avoidance of doubt, when we refer to areal density herein, the term refers to the average areal density calculated for a given strip, strand, piece or sheet of aerosol-generating material; It is calculated by measuring the surface area and weight of a given strip, strand, piece or sheet of product material.

The sheet or shredded sheet of aerosol-generating material has an areal density of about 100 g/m ² to about 250 g/m ² . The sheet or shredded sheet may be about 110 g/m ² to about 240 g/m ² , about 120 g/m ² to about 230 g/m ² , about 130 g/m ² to about 220 g/m ² , or about 140 g/m ² to It may have an areal density of about 210 g/m ² . In some embodiments, the sheet or shredded sheet is about 130 g/m ² to about 190 g/m 2 , about 140 g/m ² to about 180 g/m ² , about 150 g/ ^{m 2 to} about 170 g/m ² It has areal density. In some embodiments, the sheet or shredded sheet has an areal density of about 180 g/m ² .

It is believed that an areal density of about 100 g/m ² to about 250 g/m ² contributes to the strength and flexibility of the sheet or shredded sheet. Additionally, the inventors have determined that a rod containing shredded sheets of aerosol-generating material having an areal density of about 180 gsm and a minimum thickness of 220-230 μm has a desired weight of tobacco material within the rod (e.g., about 300 mg). Filled so that the aerosol-generating material remains in place within the rod while maintaining and delivering acceptable organoleptic properties (e.g., taste and odor) when heated within a non-flammable aerosol delivery device. I found out that it can be done.

It is believed that the flexibility of the sheet or shredded sheet depends, at least in part, on the thickness and areal density of the sheet or shredded sheet. Thicker or shredded sheets may be less flexible than thinner or shredded sheets. Also, the higher the areal density of the sheet, the lower the flexibility of the sheet or shredded sheet. It is believed that the combination of aerosol-generating material thickness and areal density described herein results in a relatively flexible sheet or shredded sheet. This flexibility may result in a variety of advantages when the aerosol-generating material is incorporated into articles for use in non-flammable aerosol delivery devices. For example, the strands or strips can easily deform and bend when the aerosol generator is inserted into the aerosol-generating material, thus facilitating insertion of the aerosol generator (e.g., heater) into the material. and improved retention of the aerosol generator by the aerosol-generating material.

The inventors have discovered that the areal density of a sheet or shredded sheet of aerosol-generating material affects the roughness of the first and second surfaces of the sheet or shredded sheet. By changing the areal density, the roughness of the first and/or second surface can be adjusted.

The sheet or shredded sheet can have a tensile strength of at least 4N/15mm. We believe that if the sheet or shredded sheet has a tensile strength of less than 4N/15mm, the sheet or shredded sheet is suitable for use in articles for use in non-flammable aerosol delivery systems during and/or subsequent manufacture. It has been found that tearing, breakage, or other deformation is likely to occur during assembly. Tensile strength can be measured using ISO 1924:2008.

The sheet or shredded sheet of aerosol-generating material may have a burst strength of at least about 75 g, at least about 100 g, or at least about 200 g. In some embodiments, the burst strength of the sheet or shredded sheet of aerosol-generating material is at least 150 g. As disclosed and discussed above, burst strength affects the strength of a material.

The sheet or shredded sheet of aerosol-generating material may have a total volatile content of about 9-13% by weight. The total volatile content may be about 5%, 10%, 15%, 20%, 25%, 30%, 40% by weight. As disclosed herein, the present invention advantageously preserves the amount of volatile compounds. This improves the flavor, taste and mouthfeel characteristics of the aerosol produced in the final product.

The aerosol-generating material may include the substance that is delivered to the user. In some embodiments, the substance delivered comprises an active substance.

An active substance as used herein may be a physiologically active substance, which is a substance intended to obtain or enhance a physiological response. The active substance may be selected, for example, from dietary supplements, nootropics, psychotropic drugs. The active substance may be naturally occurring or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, thein, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or components, derivatives or combinations thereof. The active substance may include one or more components, derivatives or extracts of tobacco, cannabis or another botanical substance.

In some embodiments, the active agent includes nicotine. In some embodiments, the active agent includes caffeine, melatonin or vitamin B12.

As described herein, the active agent may include one or more components, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.

As described herein, the active substance may include or be derived from one or more botanical substances or components, derivatives or extracts thereof. As used herein, the term "plant material" includes, but is not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, rinds, shells, etc. , including any material of plant origin. Alternatively, the materials may include synthetically derived active compounds that occur naturally in plants. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, strips, strips, sheets, etc. Examples of botanicals are tobacco, eucalyptus, star anise, hemp, cacao, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel. , licorice, matcha, yerba mate, orange skin, papaya, rose, sage, teas such as green and black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, Nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, turmeric, turmeric, sandalwood, coriander, bergamot, orange blossom, myrtle, cassis, Valerian, bell pepper, mace, damien, marjoram, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or these Any combination of Mint can be selected from the following mint varieties: Mentha arventis, Mentha c. v. , Mentha niliaca, Mentha piperita, Mentha piperita citrata c. v. (Mentha piperitacitratac.v.), Mentha piperita c. v. (Mentha piperitac.v.), Mentha spicata crispa, Mentha cordifolia, Mentha longifolia, Mentha suaveolens variegata ( Mentha suaveolens variegata)・Mentha pulegium, Mentha spicata c. v. , and Mentha suaveolens.

In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives or extracts thereof, and the botanical substance is tobacco.

In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives or extracts thereof, the botanical substances being from eucalyptus, star anise, cocoa and hemp. selected.

In some embodiments, the active agent comprises or is derived from one or more botanicals or components, derivatives or extracts thereof, and the botanicals are selected from rooibos and fennel.

In some embodiments, the first composition, the second composition, a mixture of the first composition and the second composition, or the aerosol-generating material before or after the extrusion, drying or shredding step. Additives may also be incorporated. In some embodiments, the additive includes the substance to be delivered.

In some embodiments, the substance delivered includes a fragrance. Flavoring agents can be added at any stage in the manufacture of the aerosol-generating material.

In some embodiments, a fragrance is added to the first composition. This embodiment enjoys the advantage that the liquid perfume is added to the liquid composition before mixing the first and second compositions and that the perfume is uniformly distributed throughout at least the first composition. do. This embodiment has the disadvantage that perfume may be lost during the drying operation.

In some embodiments, flavoring may be added after the shredding operation. For example, the machine may be equipped with a perfume nozzle for applying perfume to the surface of the strip of aerosol-generating material.

As used herein, the terms "flavoring" and "flavoring" are used to create a desired taste, aroma or other somatic sensation in a product intended for adult consumers, to the extent local regulations permit. Refers to the materials that can be used. These materials may be naturally occurring flavor substances, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol). , magnolia, chamomile, fenugreek, cloves, maple, matcha, menthol, mentha, aniseed (aniseed), cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherries, berries, red berries, cranberries, peaches, Apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus, 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, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil from any species of the Mentha genus, eucalyptus, star anise, cacao, Lemongrass, rooibos, flax, biloba, hazel, hibiscus, laurel, yerba mate, orange skin, rose, teas such as green and black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary. , saffron, lemon peel, mint, beefsteak plant, turmeric, coriander, myrtle, blackcurrant, valerian, bell pepper, mace, damian, marjoram, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter receptor site blockers, sensory receptor site activators or stimulants, sugars and/or sugar substitutes (e.g. sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose) , fructose, sorbitol, mannitol), as well as other additives such as charcoal, chlorophyll, minerals, botanicals, breath fresheners, etc. These materials may be imitations, synthetic components, natural components, or blends thereof. These materials may be in any suitable form, for example liquids such as oils, solids such as powders, or gases.

In some embodiments, the flavor comprises menthol, spearmint and/or peppermint. In some embodiments, the flavor comprises cucumber, blueberry, citrus fruit, and/or red berry flavor ingredients. In some embodiments, the fragrance includes eugenol. In some embodiments, the flavor comprises flavor components extracted from tobacco. In some embodiments, the flavoring comprises flavor components extracted from cannabis.

In some embodiments, the delivered substance is usually chemically induced and is perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of the olfactory or gustatory nerves. Sensory agents intended to produce a somatosensorial sensation may also be included, which may include chemicals that produce a warming, cooling, tingling, numbing effect. Suitable warming effect agents include, but are not limited to, vanillyl ethyl ether, and suitable cooling effect agents include eucolyptol and WS-3. However, it is not limited to this.

In some embodiments, the first composition, the second composition, or a mixture of the first and second compositions may contain one or more functional materials. . The one or more other functional materials may include one or more of pH modifiers, colorants, preservatives, binders, fillers, stabilizers, and/or antioxidants.

In some embodiments, the substance delivered may be an aerosol-generating material, as described herein, or a material not intended to be aerosolized. Optionally, either material may include one or more active ingredients, one or more fragrances, one or more aerosol formers, and/or one or more other functional materials.

According to one aspect of the present disclosure, a consumable article comprising an aerosol-generating material described herein is provided. A consumable item is an article comprising an aerosol-generating material, some or all of which is intended to be consumed during use by a user. The consumable may include one or more components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol-generating region, a housing, a wrapper, a mouthpiece, a filter, and/or an aerosol modifier. The consumable may also include an aerosol generator, such as a heater, that generates heat to generate an aerosol from the aerosol-generating material when used. The heater may include, for example, a combustible material, a conductively heatable material, or a susceptor. The consumable may be any shape or size suitable for a smoking device. In some embodiments of the invention, the consumable is rod-shaped.

In one aspect, an aerosol-generating material is provided to an aerosol-generating device, such as a tobacco heated product (THP) or a hybrid e-cigarette product.

As used herein, the term "delivery system" is intended to encompass systems that deliver at least one substance to a user, including:
Cigarettes, cigarillos, cigars, pipe tobacco, make-your-own tobacco, etc. (based on tobacco, tobacco derivatives, puffed tobacco, recycled tobacco, tobacco substitutes, or other smoking materials) combustible aerosol delivery systems, regardless of whether the aerosol-generating material is combusted; and e-cigarettes, tobacco heating products, or hybrid systems that use a combination of aerosol-generating materials to generate an aerosol; A nonflammable aerosol delivery system that releases

According to the present disclosure, a "flammable" aerosol delivery system includes an aerosol-generating material (or a component thereof) that is a component of the aerosol delivery system to facilitate delivery of at least one substance to a user. , a system that burns or is burnt during use.

In some embodiments, the delivery system is a combustible aerosol delivery system, such as a system selected from the group consisting of cigarettes, cigarillos, and cigars.

In some embodiments, the present disclosure provides an aerosol modifier releasing component such as a filter, filter rod, filter segment, tobacco rod, spill, or capsule, string, or bead, or plug wrap, tipping paper, or cigarette paper. Relating to components for use in flammable aerosol delivery systems, such as paper.

According to the present disclosure, a "non-flammable" aerosol delivery system includes an aerosol-generating material (or a component thereof) that is a component of the aerosol delivery system to facilitate delivery of at least one substance to a user. It is a non-combustible or non-combustible system.

In some embodiments, the delivery system is a non-flammable aerosol delivery system, such as a powered non-flammable aerosol delivery system.

In some embodiments, the non-flammable aerosol delivery system is an electronic cigarette, also known as a vape device or electronic nicotine delivery system (END), where the presence of nicotine in the aerosol-generating material is a requirement. Please note that this is not the case.

In some embodiments, the non-flammable aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heated system. An example of such a system is a tobacco heating system.

In some embodiments, the non-flammable aerosol delivery system is a hybrid system that uses a combination of aerosol-generating materials (one or more of which may be heated) to generate an aerosol. Each aerosol-generating material may be in solid, liquid or gel form, for example, and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. Solid aerosol-generating materials may include, for example, tobacco or non-tobacco products.

Typically, a non-flammable aerosol delivery system may include a non-flammable aerosol delivery device and consumables for use with the non-flammable aerosol delivery device.

In some embodiments, the present disclosure relates to a consumable that includes an aerosol-generating material and is configured for use with a non-flammable aerosol delivery device. These consumables are sometimes referred to as articles throughout this disclosure.

In some embodiments, a non-flammable aerosol delivery system, such as a non-flammable aerosol delivery device, may include a power source and a controller. The power source may be, for example, a power source or a heat source. In some embodiments, the heat source comprises a carbon substrate that can generate energy in the form of heat to power an aerosol generating material or heat transfer material proximate to the heat source.

In some embodiments, a non-flammable aerosol delivery system may include a region for containing consumables, an aerosol generator, an aerosol generation region, a housing, a mouthpiece, a filter, and/or an aerosol modifier.

In some embodiments, consumables for use with a non-flammable aerosol delivery device include an aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol-generating area, a housing, a wrapper, a filter. , a mouthpiece, and/or an aerosol modifier.

In some embodiments, the substance delivered may be an aerosol-generating material or a material not intended to be aerosolized. Optionally, either material may include one or more active ingredients, one or more fragrances, one or more aerosol formers, and/or one or more other functional materials.

As disclosed herein, a non-flammable aerosol delivery system may include an aerosol-generating material. This is illustrated in FIGS. 2 and 3.

FIG. 2 is a side cross-sectional view of a consumable or article 1 for use in an aerosol delivery system. Article 1 comprises a mouthpiece segment 2 and an aerosol generating segment 3.

The aerosol-generating segment 3 is cylindrical rod-shaped and contains an aerosol-generating material 4 . The aerosol generating material can be any of the materials discussed herein.

Although described above in the form of a rod, the aerosol-generating segment 3 may also be provided in other forms, for example in the form of a plug, pouch or parcel of material within an article.

The mouthpiece segment 2 of the illustrated embodiment includes a body of material 5, such as a fibrous or filamentary tow.

The rod-shaped consumable 1 further comprises a wrapper 6, for example a paper wrapper, surrounding the mouthpiece segment 2 and the aerosol-generating segment 3.

FIG. 3 illustrates an example of a non-flammable aerosol delivery device 100 for generating an aerosol from an aerosol-generating medium/material, such as the aerosol-generating material of the consumable 110 described herein. Broadly speaking, the device 100 heats an exchangeable article 110 containing an aerosol-generating medium, such as article 1 as shown in FIG. 2, or as described elsewhere herein. , may be used to generate an aerosol or other inhalable medium that is inhaled by a user of device 100. Device 100 and replaceable article 110 together form a system.

Device 100 includes a housing 102 (in the form of an outer cover) that surrounds and houses the various parts of device 100. Device 100 has an opening 104 at one end through which an article 110 may be inserted for heating by a heating assembly. In use, article 110 may be fully or partially inserted into a heating assembly where it may be heated by one or more parts of the heating assembly.

The device 100 of this example includes a first end that includes a lid 108 that is movable relative to the first end member 106 to close the opening 104 when no article 110 is placed. A member 106 is provided. Although lid 108 is shown in an open configuration in FIG. 3, lid 108 can be moved to a closed configuration. For example, the user can slide lid 108 in the direction of arrow "B".

Device 100 may include a user-operable control element 112, such as a button or switch, that when pressed causes operation of device 100. For example, a user can turn on device 100 by operating switch 112.

Device 100 may also include electrical components such as a socket/port 114 that can receive a cable for charging a battery of device 100. For example, socket 114 may be a charging port, such as a USB charging port.

In some embodiments, consumable 110 may include an aerosol modifier. Aerosol modifiers are typically located downstream of the aerosol generation region and are configured to modify the generated aerosol, e.g., by changing the taste, flavor, sourness, or other properties of the aerosol. It is a substance. The aerosol modifier may be supplied with an aerosol modifier release component operable to selectively release the aerosol modifier.

Aerosol modifiers may be, for example, additives or adsorbents. Aerosol modifiers may include, for example, one or more of flavorants, colorants, water, and carbon adsorbents. Aerosol modifiers may be, for example, solids, liquids, or gels. Aerosol modifiers may be in powder, thread, or granule form. The aerosol modifier may not include a filter material.

In some embodiments, the device may also include an aerosol generator. An aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to thermal energy such that the aerosol-generating material releases one or more volatile substances to form an aerosol. be. In some embodiments, the aerosol generator is configured to generate an aerosol from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, pressure increase, or electrostatic energy.

Example 1
Two types of aerosol generating materials were prepared. forming a first composition (“liquid phase”) comprising at least one binder (CMC, optionally guar) and an aerosol-forming agent, tobacco material, filler, and a second binder (CMC) forming a second composition (a "dry phase") comprising: and combining the first and second compositions to form a dough of the first and second compositions. Each material was prepared by forming a mixture. The mixture was then extruded and dried below 100°C to form a sheet of aerosol-generating material. The burst strength of the two materials was measured and compared. Bursting strength was measured using a calibrated Texture Analyzer from Stable Micro Systems (load cell 50 kg, probe height calibration 20 mm, contact force 1 g) and Exponent software. Burst strength was measured using a 5 mm stainless steel ball probe using a 3 cm ² sheet of aerosolizable material. Table 1 shows the composition and bursting strength of each material.

As can be seen from Table 1, using 2% CMC in the first composition and 3% CMC in the second composition (CMC in the mixture of the first and second compositions) 5% in total), an aerosol-generating material (aerosol-generating material 2) having a burst strength of at least 150 g was obtained. Furthermore, the inventors have found that there are no major challenges in processing the material in equipment or machines, and that the burst strength is suitable for subsequent use in articles for use in non-flammable aerosol delivery systems. I found it.

Example 2
FIG. 4 shows a reduction in the volatile compound nicotine (“nicotine (nic) delta” in a dashed line pattern) in three exemplary aerosol-generating materials formed using the method of preparing aerosol-generating material 2 of Example 1. It is a graph showing the decrease in the volatile compound glycerol (indicated as "glycerol delta" in a dot pattern). Changes in the amount of glycerol and nicotine were determined from the dough mixture to the final product by gas chromatography (GC). The change in total volatile content, including water content, was measured as the percent weight loss when the sample was dried for exactly 3 hours in a ventilated hot air oven temperature controlled at 110°C.

Even when nicotine and glycerol are combined, the reduction is only 0-2%. Furthermore, the water content has only decreased by about 16%. This indicates an efficient and targeted drying process that only removes unwanted moisture and minimizes the loss of volatile compounds nicotine and glycerol. Nicotine is an example of an active agent described herein, and glycerol is an example of an aerosol-forming agent described herein.

Example 3
In this example, the physical properties of an aerosol-generating material produced by a band casting method and an aerosol-generating material produced by the method of the present invention were compared.

The various embodiments described herein are presented solely to aid in understanding and teaching the claimed features. These embodiments are provided as representative examples of embodiments only and are not intended to be exhaustive and/or exclusive. The advantages, embodiments, examples, features, features, structures, and/or other aspects described herein are limitations on the scope of the invention as defined by the claims, or limitations on the equivalents of the claims. It is to be understood that other embodiments may be utilized and changes may be made without departing from the scope of the claimed invention. Various embodiments of the invention suitably include suitable combinations of disclosed elements, components, features, parts, steps, means, etc. other than those specifically described herein; It may consist of or consist essentially of these. Additionally, this disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims (26)

forming a first composition including a first binder and an aerosol-forming agent;
forming a second composition comprising a tobacco material, a filler, and optionally a second binder;
combining the first composition and the second composition to form a mixture of the first composition and the second composition, wherein the mixture agent, the second binder, and the filler in a total amount between about 5% and about 15% by weight of the mixture; and
A method for preparing an aerosol-generating material, comprising processing the mixture of the first composition and the second composition to form an aerosol-generating material. The method of claim 1, wherein processing the mixture of the first composition and the second composition comprises extruding the mixture to form a sheet of the aerosol-generating material. . 3. The method of claim 2, comprising drying the sheet of aerosol-generating material. 4. The method of any one of claims 1-3, wherein the mixture of the first composition and the second composition has a volatile content of greater than about 20% by weight. 5. According to any one of claims 1 to 4, the aerosol-generating material has a volatile content that is less than the volatile content of the mixture of the first composition and the second composition. the method of. 6. The method of any one of claims 1-5, wherein the aerosol-generating material has a volatile content of less than about 20% by weight. A method according to any one of claims 1 to 6, wherein the tobacco material comprises particulate tobacco. A method according to any one of claims 1 to 7, wherein the tobacco material has a particle size distribution (D90) of 160 to 450 μm. A method according to any one of claims 1 to 8, wherein the first binder and the second binder are the same or different. 10. The method of any preceding claim, wherein the ratio of the first binder to the second binder is from 1:1 to about 1:10. the mixture of the first composition and the second composition comprises the binder in an amount greater than about 2% by weight of the mixture of the first composition and the second composition; , the method according to any one of claims 1 to 10. said mixture of said first composition and said second composition in a total amount between 5 and 15% by weight of said mixture of said first composition and said second composition; 12. A method according to any one of claims 1 to 11, comprising one binder, said second binder and said filler. A method according to any one of claims 1 to 12, wherein the first composition is in liquid phase and the second composition is in solid phase. the mixture of the first composition and the second composition comprises the filler in an amount greater than about 2% by weight of the mixture of the first composition and the second composition; A method according to any one of claims 1 to 13. A method according to any one of claims 2 to 14, comprising the step of shredding the sheet to form strips of the aerosol-generating material. 16. A method according to any one of claims 3 to 15, wherein said drying is carried out at a temperature below about 100°C. 17. The mixture of the first composition and the second composition is formed by homogenizing the first composition and the second composition. The method described in paragraph (1). Aerosol-generating material prepared by the method according to any one of claims 1 to 17. 19. The aerosol-generating material of claim 18 in the form of a sheet or shredded sheet. 20. The aerosol-generating material of claim 19, wherein the sheet or shredded sheet has a burst strength of at least 150 g. An aerosol-generating material according to any one of claims 18 to 20, wherein the sheet or shredded sheet has an areal density of about 170 g/m ² to about 240 g/m ² . An aerosol-generating material according to any one of claims 18 to 21, wherein the sheet or shredded sheet has a tensile strength of about 4 N/15 mm to about 20 N/15 mm. Claims 18 to 18, comprising an amount of glycerol and/or nicotine that is 0 to 5% by weight less than the amount of glycerol and/or nicotine contained in the mixture of the first composition and the second composition. 23. The aerosol-generating material according to any one of 22. Article for use in a non-flammable aerosol delivery system, comprising an aerosol-generating material according to any one of claims 18 to 23. 25. A non-flammable aerosol delivery system comprising the article of claim 24. Use of an aerosol-generating material according to any one of claims 18 to 25 in an article for use in a non-flammable aerosol delivery system.

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