WO2023002020A1

WO2023002020A1 - Aerosol generation

Info

Publication number: WO2023002020A1
Application number: PCT/EP2022/070635
Authority: WO
Inventors: Walid Abi Aoun
Original assignee: Nicoventures Trading Limited
Priority date: 2021-07-22
Filing date: 2022-07-22
Publication date: 2023-01-26
Also published as: GB202110557D0; IL310091A; CA3226551A1

Abstract

The present invention relates to methods of forming an aerosol-generating material; aerosol-generating materials obtainable by the method; aerosol-generating compositions comprising the aerosol-generating material; articles for use within a non-combustible aerosol provision system comprising the aerosol-generating composition; and non-combustible aerosol provision systems. The methods comprise: providing a slurry comprising gelling agent, aerosol-former and a solvent; forming a layer of the slurry; drying the slurry; and applying an active or flavourant during and/or after the drying step.

Description

AEROSOL GENERATION

Technical Field The present invention relates to a method of making an aerosol-generating material, aerosol-generating material obtainable or obtained by said method, and articles and systems incorporating said aerosol-generating material.

Background Smoking articles such as cigarettes, cigars and the like burn tobacco during use to create tobacco smoke. Alternatives to these types of articles release an inhalable aerosol or vapour by releasing compounds from a substrate material by heating without burning. These may be referred to as non-combustible smoking articles or aerosol generating assemblies or non-combustible aerosol provision systems.

One example of such a product is a heating device which release compounds by heating, but not burning, a solid aerosol-generating composition. This solid aerosol generating composition may, in some cases, contain a tobacco material. The heating volatilises at least one component of the material, typically forming an inhalable aerosol. These products may be referred to as heat-not-burn devices, tobacco heating devices or tobacco heating products. Various different arrangements for volatilising at least one component of the solid aerosol-generating material are known. As another example, there are hybrid devices. These hybrid devices contain a liquid source (which may or may not contain nicotine) which is vaporised by heating to produce an inhalable vapour or aerosol. The device additionally contains a solid aerosol-generating composition (which may or may not contain a tobacco material) and components of this material are entrained in the inhalable vapour or aerosol to produce the inhaled medium. Summary

A first aspect of the invention provides a method of forming an aerosol generating material comprising aerosol-former, gelling agent and active or flavourant, the method comprising: (a) providing a slurry comprising the gelling agent, aerosol-former, a solvent and any optional further components of the aerosol-generating material;

(b) forming a layer of the slurry;

(c) drying the slurry; and

(d) applying the active or flavourant during and/or after the drying step (c) to form the aerosol-generating material.

A second aspect of the invention provides a method of forming an aerosol generating material comprising aerosol-former, gelling agent and active or flavourant, the method comprising: (a) providing a slurry comprising the gelling agent and a solvent;

(b) forming a layer of the slurry;

(c) drying the slurry; and

(d) applying (i) the active or flavourant and (ii) the aerosol-former, during and/or after the drying step (c).

In the second aspect, step (d) may comprise combining the active or flavourant and the aerosol-former to form a mixture, and applying said mixture during and/or after the drying step (c). That is, the active or flavourant and the aerosol-former may be applied together. Alternatively, the active or flavourant and the aerosol-former may be applied separately.

A third aspect of the invention provides an aerosol-generating material obtainable or obtained by methods of the first or second aspects. A fourth aspect of the invention provides an article for use in a non-combustible aerosol provision system, the article comprising an aerosol-generating material according to the third aspect. Such articles may alternatively be referred to herein as an aerosol generating article, consumable or the like. A fifth aspect of the invention provides a non-combustible aerosol provision system comprising the article according to the fourth aspect and a non-combustible aerosol provision device, the non-combustible aerosol provision device comprising an aerosol-generation device configured to generate aerosol from the article when the article is used with the non-combustible aerosol provision device. In some cases, the device may comprise a heater which is configured to heat the aerosol-generating material without burning. Such systems may alternatively be referred to herein as an aerosol generating assembly.

In embodiments, the active or flavourant is volatile or semi-volatile. In embodiments, the active or flavourant is volatile.

In embodiments, the active or flavourant comprises (or is selected from the group consisting of) ethyl isobutyrate, hexanal, isoamyl acetate, 2,3,5-trimethyl pyrazine, 6-methyl-5-hepten-2-one, isovaleric acid, benzaldehyde, isoamyl isovalerate, guaiacol, methyl cyclopentenolone, hexanoic acid, menthol, gamma- hexalactone, benzyl carbinol, acetyl pyrazine, trans-anethole, piperonal, beta- caryophyllene, beta-damascenone, phenylacetic acid, beta-ionone, veratraldehyde, vanillin, 5-propenyl guaethol, gamma-nonalactone, omega-pentadecalactone, or combinations thereof.

In embodiments, the active or flavourant comprises (or is selected from the group consisting of) ethyl isobutyrate, hexanal, isoamyl acetate, 2,3,5-trimethyl pyrazine, 6-methyl-5-hepten-2-one, isovaleric acid, benzaldehyde, isoamyl isovalerate, guaiacol, methyl cyclopentenolone, hexanoic acid, menthol, gamma- hexalactone, benzyl carbinol, acetyl pyrazine, trans-anethole, or combinations thereof.

In embodiments, the active orflavourant comprises or is menthol.

In embodiments, the active orflavourant comprises a constituent, derivative or extract of cannabis.

In embodiments, the active orflavourant comprises a cannabinoid.

In embodiments, the active orflavourant comprises CBD. In embodiments, the active orflavourant comprises one or more terpenes or a derivative thereof. The one or more terpenes or a derivative thereof may be selected from linalool, limonene, beta-caryophyllene, beta-citronellol, linalyl acetate, eucalyptol, caryophyllene oxide, phytol, fenchol, nerolidol, alpha-terpineol, camphene, alpha- pinene, ocimene, alpha-bisabolol, valencene, geranyl acetate, myrcene, trans- caryophyllene, terpinolene, beta-pinene, alpha-humulene, guaiol, and combinations thereof.

In embodiments, the active orflavourant is applied during the drying step (c).

In embodiments, the active orflavourant is applied after the drying step (c).

In embodiments, the aerosol-generating material comprises 0.5-60 wt% gelling agent; and/or the aerosol-generating material comprises 5-80 wt% aerosol-former; and/or the aerosol-generating material comprises up to 60 wt% active orflavourant.

In embodiments, the aerosol-former comprises one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3- butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. The aerosol-former may comprise glycerol or a combination of glycerol and propylene glycol.

In embodiments, the gelling agent comprises one or more compounds selected from polysaccharide gelling agents, such as alginate, pectin, starch or a derivative thereof, cellulose or a derivative thereof, pullulan, carrageenan, agar and agarose; gelatin; gums, such as xanthan gum, guar gum and acacia gum; silica or silicone compounds, such as PDMS and sodium silicate; clays, such as kaolin; and polyvinyl alcohol. The gelling agent may be a cellulose derivative, such as hydroxyl methyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose (CMC), hydroxypropyl methylcellulose (HPMC, methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), or cellulose acetate propionate (CAP). In embodiments, the gelling agent is CMC. In embodiments, the gelling agent is not crosslinked.

In embodiments, the aerosol-generating material comprises filler.

In embodiments, the active orflavourant is sprayed in step (d).

In embodiments, the solvent comprises or is water. Further features and advantages of the invention will become apparent from the following description, given by way of example only, and with reference to the accompanying figures.

Brief Description of the Figures

Figure 1 shows a section view of an example of an article.

Figure 2 shows a perspective view of the article of Figure 1.

Figure 3 shows a sectional elevation of an example of an article.

Figure 4 shows a perspective view of the article of Figure 3. Figure 5 shows a perspective view of an example of a non-combustible aerosol provision system.

Figure 6 shows a section view of an example of a non-combustible aerosol provision system.

Figure 7 shows a perspective view of an example of a non-combustible aerosol provision system.

Figure 8 shows an exploded diagram of an example consumable.

Figure 9 shows an example of a consumable comprising a plurality of discrete portions of aerosol-generating material. Detailed Description

The method described herein generates an aerosol-generating material which may be an “amorphous solid”. In some embodiments, the aerosol-generating material comprises an aerosol-generating film that is an amorphous solid. In some embodiments, the amorphous solid is a “monolithic solid”. The aerosol-generating material may be non-fibrous or fibrous. For example, the aerosol-generating material may be substantially non-fibrous. In some embodiments, the aerosol-generating material may be a “dried gel”. The aerosol-generating material is a solid material that may retain some fluid, such as liquid, within it.

As described above, the invention provides a method of forming an aerosol generating material comprising aerosol-former, gelling agent and active or flavourant, the method comprising:

(a) providing a slurry comprising the gelling agent, aerosol-former, a solvent and any optional further components of the aerosol-generating material;

(b) forming a layer of the slurry;

(c) drying the slurry; and

The invention also provides a method of forming an aerosol-generating material comprising aerosol-former, gelling agent and active or flavourant, the method comprising:

(a) providing a slurry comprising the gelling agent and a solvent;

(b) forming a layer of the slurry;

(c) drying the slurry; and

The loss of active or flavourant during manufacture of the aerosol-generating material can be a problem. For example, it has previously been found that up to 40% of menthol may be lost during manufacture of an aerosol-generating material containing menthol. This loss of active or flavourant during manufacturer is also an issue for other actives or flavourants, particularly those which are semi-volatile or volatile, such as menthol. The active or flavourant is usually lost during the drying process by evaporation. Without wishing to be bound by theory, it is believed that applying the active or flavourant during and/or after the drying step helps to prevent or minimise the loss of active and/or flavourant during the drying step. This is particularly important if the active or flavourant is highly volatile. Loss of the active or flavourant can be minimised by applying the active or flavourant after the drying step.

Additionally, it is believed that applying the active or flavourant during and/or after the drying step can enable components which might be immiscible with the slurry (e.g. terpenes) to be more easily added to the aerosol-generating material.

Similarly, applying the aerosol-former during and/or after the drying step may help to prevent or minimise the loss of aerosol-former during the drying step.

The active or flavourant and/or the aerosol-former are applied directly to the slurry.

In one aspect, the aerosol-former is applied during the drying step and the active or flavourant is applied after the drying step.

In one aspect, the active or flavourant is applied during the drying step and the aerosol-former is applied after the drying step.

In one aspect, the active or flavourant and the aerosol-former are both applied after the drying step. In this case the active or flavourant and the aerosol-former may be applied together or separately.

In embodiments, the active or flavourant is applied neat (i.e. absent any solvent), particularly if it is a liquid under the application conditions. Alternatively, the active or flavourant may be applied neat (i.e. absent any solvent) when the active or flavourant is solid under the application conditions, for example by applying the active or flavourant in powder or particulate form.

In embodiments, the active or flavourant is dissolved in a solvent before it is applied. Suitable solvents include, for example, ethanol. Thus, in embodiments the active orflavourant is dissolved in a solvent such as ethanol, and the solution is applied during and/or after the drying step (c).

Alternatively, the aerosol-former may act as a suitable solvent. Thus, in embodiments the active or flavourant is dissolved in the aerosol-former, and the solution is applied during and/or after the drying step (c).

In one aspect, the active or flavourant may be applied during the drying step (c). This is useful where it is desired for the active or flavourant to be dispersed within the aerosol-generating material, and/or where the active orflavourant is not volatile.

Thus, in one aspect, the active orflavourant comprises a cannabinoid, and said active or flavourant may be applied during the drying step (c).

In another aspect, the active orflavourant may be applied after the drying step (c). This is useful where it is not desired for the active or flavourant to be dispersed within the aerosol-generating material, and/or where the active or flavourant is semi volatile or volatile.

Thus, in one aspect, the active or flavourant comprises menthol or a terpene or a derivative thereof, and said active orflavourant may be applied during the drying step (c).

If more than one active or flavourant is present one active or flavourant may be applied during the drying step (c), and another (different) active orflavourant may be applied after the drying step (c). This may be useful if the first active (which is applied during the drying step) is less volatile than the second active (which is applied after the drying step) and/or if it is important for the first active to be homogeneously distributed throughout the aerosol-generating material.

In one embodiment, the active orflavourant is sprayed during and/or after the drying step (c). That is, in one embodiment the active or flavourant is applied by spraying the active or flavourant.

In some cases, the drying (c) may remove from about 50wt%, 60wt%, 70wt%, 80wt% or 90wt% to about 80wt%, 90wt% or 95wt% (VWVB) of water in the slurry. In some cases, the resulting aerosol-generating material comprises from about 1wt% to about 15wt% water, calculated on a wet weight basis. Suitably, the resulting aerosol-generating material comprises from about 5wt% to about 15wt% water, calculated on a wet weight basis (WWB). Suitably, the water content of the aerosol generating material may be from about 5wt%, 7wt% or 9wt% to about 15wt%, 13wt% or 11wt% (WWB), most suitably about 10wt%.

If the water content of the aerosol-generating material is too high, its performance in use is compromised. The high heat capacity of water means that if the water content is too high, more energy is needed to generate an aerosol, reducing operating efficiency. Further, if the water content is too high, the puff profile may be less satisfactory to the consumer due to the generation of hot and humid puffs (a sensation known in the field as “hot puff’). Moreover, if the water content is too high, microbial growth may occur. Conversely, if the water content is too low, the material may be brittle and difficult to handle. The hygroscopic nature of the aerosol forming material may mean that water is drawn into the material from the atmosphere if the water content is too low, destabilising the material. In some cases, the drying results in an aerosol-generating material which has a thickness that is between about 5% and 20% of the slurry thickness, suitably about 10%. In some cases, the aerosol-generating material may have a thickness of about 0.015mm to about 1.0mm. Suitably, the thickness may be in the range of about 0.05mm, 0.1mm or 0.15mm to about 0.5mm or 0.3mm. A material having a thickness of 0.2mm is particularly suitable. The aerosol-generating material may comprise more than one layer, and the thickness described herein refers to the aggregate thickness of those layers.

In some cases, the method comprises forming a layer of the slurry which is less than about 4mm thick. Suitably, the thickness of the slurry layer is in the range of about 1mm to about 3mm, suitably about 1.5mm to about 2.5mm. In some cases, the thickness of the slurry layer is about 2mm. If the slurry layer is too thick, it can be difficult to dry to form an aerosol generating material with the required water content, whilst minimising cracking of the solid on drying.

If the aerosol-generating material is too thick, then heating efficiency is compromised. This adversely affects the power consumption in use. Conversely, if the aerosol-generating material is too thin, it is difficult to manufacture and handle; a very thin material is harder to cast and may be fragile, compromising aerosol formation in use.

Any thickness stipulated herein is a mean thickness. In some cases, the thickness may vary by no more than 25%, 20%, 15%, 10%, 5% or 1%.

In some cases, the drying (c) comprises flowing air over the gel, wherein the air temperature is in the range of about 80°C to about 140°C. In some cases, the air flow speed is less than about 30m/s, and is suitably in the range of 10m/s to 30m/s. In some cases, the air flow speed is about 20 m/s.

In some cases, the drying (c) comprises heating the gel for less than about 40 minutes, 30 minutes or 20 minutes. In some cases, it comprises heating the gel for at least about 10 minutes.

In some cases, the drying (c) comprises heating the gel to a temperature in the range of about 80°C, 85°C or 90°C to about 130°C, 120°C or 110°C.

In some cases, the surface temperature of the gel during drying does not exceed about 100°C.

In some cases, the slurry is set to form a gel prior to drying step (c). In this case, the slurry may also comprise a setting agent. For example, the slurry may comprise sodium, potassium or ammonium alginate as a gelling agent, and a setting agent comprising a calcium source (such as calcium chloride or calcium lactate), may be added to the slurry to form a calcium alginate gel. In some cases, the setting agent may be sprayed onto the slurry after step (b). In examples, the setting agent comprises or consists of calcium acetate, calcium formate, calcium carbonate, calcium hydrogencarbonate, calcium chloride, calcium lactate, or a combination thereof. In some examples, the setting agent comprises or consists of calcium formate and/or calcium lactate. In particular examples, the setting agent comprises or consists of calcium formate. Typically, employing calcium formate as a setting agent results in an aerosol-generating having a greater tensile strength and greater resistance to elongation.

The total amount of the setting agent, such as a calcium source, may be 0.5- 5wt% (calculated on a dry weight basis). Suitably, the total amount may be from about 1wt%, 2.5wt% or 4wt% to about 4.8wt% or 4.5wt%. The addition of too little setting agent may result in an aerosol-generating material which does not stabilise the aerosol-generating material components and results in these components dropping out of the aerosol-generating material. The addition of too much setting agent results in an aerosol-generating material that is very tacky and consequently has poor handleability.

Suitably, the weight ratio of setting agent to gelling agent may be from about 1:5 to 1:15, suitably about 1:10.

When the aerosol-generating material does not contain tobacco, a higher amount of setting agent may need to be applied. In some cases the total amount of setting agent may therefore be from 0.5-12wt% such as 5-10wt%, calculated on a dry weight basis. Suitably, the total amount may be from about 5wt%, 6wt% or 7wt% to about 12wt% or 10wt%. In this case the aerosol-generating material will not generally contain any tobacco.

Alginate salts are derivatives of alginic acid and are typically high molecular weight polymers (10-600 kDa). Alginic acid is a copolymer of b-D-mannuronic (M) and a-L-guluronic acid (G) units (blocks) linked together with (1 ,4)-glycosidic bonds to form a polysaccharide. On addition of calcium cations, the alginate crosslinks to form a gel. Alginate salts with a high G monomer content more readily form a gel on addition of the calcium source. In some cases therefore, the slurry may comprise an alginate salt in which at least about 40%, 45%, 50%, 55%, 60% or 70% of the monomer units in the alginate copolymer are a-L-guluronic acid (G) units. In some examples, the slurry has a viscosity of from about 10 to about 20 Pa-s at 46.5 °C, such as from about 14 to about 16 Pa-s at 46.5 °C. In some cases, the slurry layer is formed by casting the slurry.

In some cases, a carrier is provided and the slurry is shaped on the carrier. The carrier functions as a support on which the aerosol-generating material layer forms, easing manufacture. The carrier may provide rigidity to the aerosol-generating material, easing handling. The carrier may be any suitable material which can be used to support an aerosol-generating material. In some cases, the carrier may be formed from materials selected from metal foil, paper, carbon paper, greaseproof paper, ceramic, carbon allotropes such as graphite and graphene, plastic, cardboard, wood or combinations thereof. In some cases, the carrier may comprise or consist of a tobacco material, such as a sheet of reconstituted tobacco. In some cases, the carrier may be formed from materials selected from metal foil, paper, cardboard, wood or combinations thereof. In some cases, the carrier comprises paper. In some cases, the carrier itself be a laminate structure comprising layers of materials selected from the preceding lists. In some cases, the carrier may also function as a flavour carrier. For example, the carrier may be impregnated with a flavourant or with tobacco extract.

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

In some cases, the carrier may be non-magnetic.

In some cases, the carrier may be magnetic. This functionality may be used to fasten the carrierto the assembly in use, or may be used to generate particular aerosol generating material shapes. In some cases, the aerosol-generating material may comprise one or more magnets which can be used to fasten the solid to an induction heater in use. In some cases, the carrier may be substantially or wholly impermeable to gas and/or aerosol. This prevents aerosol or gas passage through the carrier layer, thereby controlling the flow and ensuring it is delivered to the user. This can also be used to prevent condensation or other deposition of the gas/aerosol in use on, for example, the surface of a heater provided in a non-combustible aerosol provision system. Thus, consumption efficiency and hygiene can be improved in some cases.

In some cases, the surface of the carrier that abuts the aerosol-generating material may be porous. For example, in one case, the carrier comprises paper. A porous carrier such as paper is particularly suitable for the present invention; the porous (e.g. paper) layer abuts the aerosol-generating material layer and forms a strong bond. The aerosol-generating material is formed by drying a gel and, without being limited by theory, it is thought that the slurry from which the gel is formed partially impregnates the porous carrier (e.g. paper) so that when the gel sets and forms cross links, the carrier is partially bound into the gel. This provides a strong binding between the gel and the carrier (and between the dried gel and the carrier).

Additionally, surface roughness may contribute to the strength of bond between the aerosol-generating material and the carrier. The paper roughness (for the surface abutting the carrier) may suitably be in the range of 50-1000 Bekk seconds, suitably 50-150 Bekk seconds, suitably 100 Bekk seconds (measured over an air pressure interval of 50.66-48.00 kPa). (A Bekk smoothness tester is an instrument used to determine the smoothness of a paper surface, in which air at a specified pressure is leaked between a smooth glass surface and a paper sample, and the time (in seconds) for a fixed volume of air to seep between these surfaces is the "Bekk smoothness”.)

Conversely, the surface of the carrier facing away from the aerosol-generating material may be arranged in contact with the heater, and a smoother surface may provide more efficient heat transfer. Thus, in some cases, the carrier is disposed so as to have a rougher side abutting the aerosol-generating material and a smoother side facing away from the aerosol-generating material.

In one particular case, the carrier may be a paper-backed foil; the paper layer abuts the aerosol-generating material layer and the properties discussed in the previous paragraphs are afforded by this abutment. The foil backing is substantially impermeable, providing control of the aerosol flow path. A metal foil backing may also serve to conduct heat to the aerosol-generating material.

In another case, the foil layer of the paper-backed foil abuts the aerosol generating material. The foil is substantially impermeable, thereby preventing water provided in the aerosol-generating material to be absorbed into the paper which could weaken its structural integrity.

In some cases, the carrier is formed from or comprises metal foil, such as aluminium foil. A metallic carrier may allow for better conduction of thermal energy to the aerosol-generating material. Additionally, or alternatively, a metal foil may function as a susceptor in an induction heating system. In particular embodiments, the carrier comprises a metal foil layer and a support layer, such as cardboard. In these embodiments, the metal foil layer may have a thickness of less than 20pm, such as from about 1 pm to about 10pm, suitably about 5pm.

In some cases, the carrier may have a thickness of between about 0.017mm and about 2.0mm, suitably from about 0.02mm, 0.05mm or 0.1mm to about 1.5mm, 1.0mm, or 0.5mm.

In some cases, the slurry may be shaped on a conductive support material. Where a carrier is present, the carrier may be provided on the conductive support material and the slurry is shaped on the carrier. The drying (c) may comprise heating the conductive support material.

In some cases, the drying (c) may comprise heating the conductive support material to at least about 100°C and flowing air over the gel, wherein the air temperature is in the range of about 80°C to about 140°C. Thus, the gel is heated from both sides. This may reduce the likelihood of delamination of the aerosol-generating material from the substrate on which it is formed, as compared to simply drying with a hot-air flow.

In some cases, the drying (c) comprises (ci) heating the conductive support material to at least about 100°C, (cii) flowing air over the gel, wherein the air temperature is in the range of about 80°C to about 140°C, and (ciii) heating the conductive support material to at least about 100°C, wherein (ci) and (cii) occur simultaneously or sequentially and (ciii) occurs after (ci) and (cii) have concluded.

The active or flavourant may be applied during or after the drying step (c). In some cases, the active orflavourant is applied during the drying step (c). This generally results in the active or flavourant being homogeneously dispersed throughout the aerosol-generating material.

In some cases, the active or flavourant is applied after drying step (c). This generally results in the active orflavourant being located on the surface of the aerosol generating material.

In some cases, the active or flavourant is applied during or after step (c) by spraying.

As mentioned above, applying (e.g. spraying) the active orflavourant after the drying step (c) is particularly advantageous when the active or flavourant is semi volatile or volatile. This is because applying (e.g. spraying) the active or flavourant during step (c), i.e. during drying, may still result in some of the active or flavourant to be lost during the remainder of the drying step (c). Thus, when the active orflavourant is semi-volatile or volatile, it is preferred that the active orflavourant is applied after the drying step (c). Volatile and semi-volatile actives and flavourants include, for example, menthol, terpenes or derivatives thereof, ketones and esters, such as ethyl butyrate, ethyl isovalerate and ethyl-2-methyl butyrate.

Other volatile and semi-volatile actives and flavourants include, but are not limited to, ethyl isobutyrate, hexanal, isoamyl acetate, 2,3,5-trimethyl pyrazine, 6- methyl-5-hepten-2-one, isovaleric acid, benzaldehyde, isoamyl isovalerate, guaiacol, methyl cyclopentenolone, hexanoic acid, menthol, gamma-hexalactone, benzyl carbinol, acetyl pyrazine, trans-anethole, piperonal, beta-caryophyllene, beta- damascenone, phenylacetic acid, beta-ionone, veratraldehyde, vanillin, 5-propenyl guaethol, gamma-nonalactone and omega-pentadecalactone.

In one aspect, the active orflavourant comprises (or is selected from the group consisting of) ethyl isobutyrate, hexanal, isoamyl acetate, 2,3,5-trimethyl pyrazine, 6- methyl-5-hepten-2-one, isovaleric acid, benzaldehyde, isoamyl isovalerate, guaiacol, methyl cyclopentenolone, hexanoic acid, menthol, gamma-hexalactone, benzyl carbinol, acetyl pyrazine, trans-anethole, piperonal, beta-caryophyllene, beta- damascenone, phenylacetic acid, beta-ionone, veratraldehyde, vanillin, 5-propenyl guaethol, gamma-nonalactone, omega-pentadecalactone, and combinations thereof. In embodiments, when the active or flavourant comprises or is one or more of these compounds, the active orflavourant is applied after the drying step (c).

In one aspect, the active orflavourant comprises (or is selected from the group consisting of) ethyl isobutyrate, hexanal, isoamyl acetate, 2,3,5-trimethyl pyrazine, 6- methyl-5-hepten-2-one, isovaleric acid, benzaldehyde, isoamyl isovalerate, guaiacol, methyl cyclopentenolone, hexanoic acid, menthol, gamma-hexalactone, benzyl carbinol, acetyl pyrazine, trans-anethole, and combinations thereof. In embodiments, when the active or flavourant comprises or is one or more of these compounds, the active or flavourant is applied after the drying step (c).

In one aspect, the active or flavourant comprises (or is) menthol. In embodiments, when the active or flavourant comprises or is menthol, the active or flavourant is applied after the drying step (c).

In one aspect, the active or flavourant comprises (or is) one or more terpenes or a derivative thereof. In embodiments, when the active or flavourant comprises one or more terpenes or a derivative thereof, the active or flavourant is applied after the drying step (c).

The one or more terpenes or a derivative thereof may be selected from linalool, limonene, beta-caryophyllene, beta-citronellol, linalyl acetate, eucalyptol, caryophyllene oxide, phytol, fenchol, nerolidol, alpha-terpineol, camphene, alpha- pinene, ocimene, alpha-bisabolol, valencene, geranyl acetate, myrcene, trans- caryophyllene, terpinolene, beta-pinene, alpha-humulene, guaiol, and combinations thereof.

In one aspect, the active orflavourant comprises (or is) a constituent, derivative or extract of cannabis, for example a cannabinoid, such as CBD. In embodiments, when the active or flavourant comprises or is a constituent, derivative or extract of cannabis, the active or flavourant is applied during or after the drying step (c). In embodiments, when the active or flavourant comprises or is a constituent, derivative or extract of cannabis, the active or flavourant is applied during the drying step (c).

Aerosol-generating material composition

In some cases, the aerosol-generating material may comprise 1-60 wt% of a gelling agent wherein these weights are calculated on a dry weight basis. Suitably, the aerosol-generating material may comprise from about 1wt%, 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, 30wt% or 27wt% of a gelling agent (all calculated on a dry weight basis). For example, the aerosol generating material may comprise 1-50wt%, 5-40wt%, 10-30wt% or 15-27wt% of a gelling agent. In some cases, the gelling agent comprises a hydrocolloid. In some cases, the gelling agent comprises 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 gelling agent comprises one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose, pullulan, xanthan gum guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol. In some cases, the gelling agent comprises alginate and/or pectin, and may be combined with a setting agent (such as a calcium source) during formation of the aerosol-generating material. In some cases, the gelling agent comprises one or more compounds selected from the group consisting of alginate and a cellulose derivative. In some cases, the aerosol-generating material may comprise a calcium-crosslinked alginate and/or a calcium-crosslinked pectin.

In some cases, the gelling agent is not cross-linked.

In some cases, the gelling agent comprises a cellulosic gelling agent. Suitable cellulosic gelling agents include hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose (CMC), hydroxypropyl methylcellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP) and combinations thereof.

In some embodiments, the gelling agent comprises (or is) one or more of hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose (HPMC), carboxymethylcellulose, guar gum, or acacia gum.

In some embodiments, the cellulosic gelling agent is CMC.

Suitably, the aerosol-generating material may comprise from about 5wt%, 10wt%, 15wt%, or 20wt% to about 80wt%, 70wt%, 60wt%, 55wt%, 50wt%, 45wt% 40wt%, or 35wt% of an aerosol-former (all calculated on a dry weight basis). The aerosol-former material may act as a plasticiser. For example, the slurry may comprise 10-60wt%, 15-50wt% or20-40wt% of an aerosol-former. In some cases, the aerosol- former comprises one or more compound selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol and xylitol. In some cases, the aerosol-former comprises, consists essentially of or consists of glycerol. If the content of the plasticiser is too high, the aerosol-generating material may absorb water resulting in a material that does not create an appropriate consumption experience in use. If the plasticiser content is too low, the aerosol-generating material may be brittle and easily broken. The plasticiser content specified herein provides an aerosol-generating material flexibility which allows the aerosol-generating material sheet to be wound onto a bobbin, which is useful in manufacture of articles for use in aerosol generation.

In some embodiments, the aerosol-former comprises one or more polyhydric alcohols, such as propylene glycol, triethylene glycol, 1 ,3-butanediol and glycerin; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and/or aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

In some cases, the aerosol-generating material may comprise a flavour. Suitably, the aerosol-generating material may comprise up to about 60wt%, 50wt%, 40wt%, 30wt%, 20wt%, 10wt% or 5wt% of a flavour. In some cases, the aerosol generating material may comprise at least about 0.5wt%, 1wt%, 2wt%, 5wt% 10wt%, 20wt% or 30wt% of a flavour (all calculated on a dry weight basis). For example, the aerosol-generating material may comprise 0.1 -60wt%, 1-60wt%, 5-60wt%, 10-60wt%, 20-50wt% or 30-40wt% of a flavour. In some cases, the flavour (if present) comprises, consists essentially of or consists of menthol. In some cases, the aerosol-generating material does not comprise a flavour.

In some cases, the aerosol-generating material comprises an active constituent. For example, in some cases, the slurry additionally comprises a tobacco material and/or nicotine. For example, the aerosol-generating material may additionally comprise powdered tobacco and/or nicotine and/or a tobacco extract. In some cases, the aerosol-generating material may comprise from about 1wt%, 5wt%, 10wt%, 15wt%, 20wt% or25wt% to about 60wt%, 50wt%, 45wt% or40wt% (calculated on a dry weight basis) of active constituent. In some cases, the aerosol-generating material may comprise from about 1wt%, 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 60wt%, 50wt%, 45wt% or 40wt% (calculated on a dry weight basis) of a tobacco material and/or nicotine.

In some cases, the aerosol-generating material comprises an active constituent such as tobacco extract. In some cases, the aerosol-generating material may comprise 5-60wt% (calculated on a dry weight basis) of tobacco extract. In some cases, the aerosol-generating material may comprise from about 1wt%, 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 55wt%, 50wt%, 45wt% or 40wt% (calculated on a dry weight basis) tobacco extract. For example, the aerosol-generating material may comprise 5-60wt%, 10-55wt% or 25-55wt% of tobacco extract. The tobacco extract may contain nicotine at a concentration such that the aerosol-generating material comprises 1wt% 1.5wt%, 2wt% or 2.5wt% to about 6wt%, 5wt%, 4.5wt% or 4wt% (calculated on a dry weight basis) of nicotine. In some cases, there may be no nicotine in the aerosol-generating material other than that which results from the tobacco extract.

In some embodiments the aerosol-generating material comprises no tobacco material but does comprise nicotine. In some such cases, the aerosol-generating material may comprise from about 1wt%, 2wt%, 3wt% or 4wt% to about 20wt%, 15wt%, 10wt% or 5wt% (calculated on a dry weight basis) of nicotine. For example, the aerosol-generating material may comprise 1-20wt% or2-5wt% of nicotine. In some embodiments, the active constituent comprises one or more cannabinoid compounds selected from the group consisting of: cannabidiol (CBD), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiolic acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabichromene (CBC), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM) and cannabielsoin (CBE), cannabicitran (CBT). The active constituent may comprise one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD) and THC (tetrahydrocannabinol).

The active constituent may comprise cannabidiol (CBD).

The active constituent may comprise nicotine and cannabidiol (CBD).

The active constituent may comprise nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol).

In some embodiments, the active constituent comprises one or more terpenes, or derivatives thereof. In this context, the term “derivatives thereof” includes, for example, terpenoids and terpene esters. In some embodiments, the one or more terpenes or derivatives thereof are monoterpenes, sesquiterpenes, terpenoids, terpene esters, or combinations thereof.

In some embodiments, the one or more terpenes or derivatives thereof may be selected from linalool, limonene, beta-caryophyllene, beta-citronellol, linalyl acetate, eucalyptol, caryophyllene oxide, phytol, fenchol, nerolidol, alpha-terpineol, camphene, alpha-pinene, ocimene, alpha-bisabolol, valencene, geranyl acetate, myrcene, trans- caryophyllene, terpinolene, beta-pinene, alpha-humulene, guaiol, and combinations thereof. In some embodiments, the one or more terpenes or derivatives thereof may comprise one or more of linalool, limonene, beta-caryophyllene, beta-citronellol, linalyl acetate, and combinations thereof.

In some cases, the total content of active constituent and/or flavour may be at least about 0.1 wt%, 1wt%, 5wt%, 10wt%, 20wt%, 25wt% or 30wt%. In some cases, the total content of active constituent and/or flavour may be less than about 60wt%, 50wt% or 40wt% (all calculated on a dry weight basis).

In some cases, the total content of tobacco material, nicotine and flavour may be at least about 0.1wt%, 1wt%, 5wt%, 10wt%, 20wt%, 25wt% or 30wt%. In some cases, the total content of tobacco material, nicotine and flavour may be less than about 60wt%, 50wt% or 40wt% (all calculated on a dry weight basis).

In some embodiments, the aerosol-generating material comprises less than 60wt% of a filler, such as from 1wt% to 60wt%, or 5wt% to 50wt%, or 5wt% to 30wt%, or 10wt% to 20wt% (all calculated on a dry weight basis).

In other embodiments, the aerosol-generating material comprises less than 20wt%, suitably less than 10wt% or less than 5wt% of a filler. In some cases, the aerosol-generating material comprises less than 1wt% of a filler, and in some cases, comprises no filler.

The filler, if present, 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 comprise one or more organic filler materials such as wood pulp, cellulose and cellulose derivatives. In particular cases, the aerosol-generating material comprises no calcium carbonate such as chalk.

In particular embodiments which include filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood pulp, hemp fibre, cellulose or cellulose derivatives. Without wishing to be bound by theory, it is believed that including fibrous filler in an aerosol-generating material may increase the tensile strength of the material. This may be particularly advantageous in examples wherein the aerosol-generating material is provided as a sheet, such as when an aerosol generating material sheet circumscribes a rod of aerosol-generating composition.

In some embodiments, the aerosol-generating material does not comprise tobacco fibres. In particular embodiments, the aerosol-generating material does not comprise fibrous material.

In some embodiments, the aerosol-generating material is substantially free from tobacco. In some embodiments, the aerosol-generating material does not comprise tobacco. In some embodiments, the aerosol-generating composition is substantially free from tobacco. In some embodiments, the aerosol-generating composition does not comprise tobacco.

In some embodiments, the aerosol-generating material is substantially free from botanical material. In some embodiments, the aerosol-generating material does not comprise botanical material.

In some embodiments, the aerosol-generating composition is substantially free from botanical material. In some embodiments, the aerosol-generating composition does not comprise botanical material.

The aerosol-generating material may have any suitable area density, such as from 30 g/m² to 120 g/m², suitably about 30 to 70 g/m², or about 40 to 60 g/m². In some embodiments, the aerosol-generating material may have an area density of from about 80 to 120 g/m², or from about 70 to 110 g/m², or particularly from about 90 to 110 g/m². Such area densities may be particularly suitable where the aerosol-generating material is included in an article/a non-combustible aerosol provision system in sheet form, or as a shredded sheet (described further hereinbelow).

The aerosol-generating material may comprise an acid. The acid may be an organic acid. In some of these embodiments, the acid may be at least one of a monoprotic acid, a diprotic acid and a triprotic acid. In some such embodiments, the acid may contain at least one carboxyl functional group. In some such embodiments, the acid may be at least one of an alpha-hydroxy acid, carboxylic acid, dicarboxylic acid, tricarboxylic acid and keto acid. In some such embodiments, the acid may be an alpha-keto acid.

In some such embodiments, the acid may be at least one of succinic acid, lactic acid, benzoic acid, citric acid, tartaric acid, fumaric acid, levulinic acid, acetic acid, malic acid, formic acid, sorbic acid, benzoic acid, propanoic and pyruvic acid.

Suitably the acid is lactic acid. In other embodiments, the acid is benzoic acid. In other embodiments the acid may be an inorganic acid. In some of these embodiments the acid may be a mineral acid. In some such embodiments, the acid may be at least one of sulphuric acid, hydrochloric acid, boric acid and phosphoric acid. In some embodiments, the acid is levulinic acid.

The inclusion of an acid is particularly preferred in embodiments in which the aerosol-generating material comprises nicotine. In such embodiments, the presence of an acid may stabilise dissolved species in the slurry from which the aerosol generating material is formed. The presence of the acid may reduce or substantially prevent evaporation of nicotine during drying of the slurry, thereby reducing loss of nicotine during manufacturing.

In certain embodiments, the aerosol-generating material comprises a gelling agent comprising a cellulosic gelling agent and/or a non-cellulosic gelling agent, an active substance and an acid.

The aerosol-generating material may comprise a colourant. The addition of a colourant may alter the visual appearance of the aerosol-generating material. The presence of colourant in the aerosol-generating material may enhance the visual appearance of the aerosol-generating material and an aerosol-generating composition comprising the aerosol-generating material. By adding a colourant to the aerosol generating material, the aerosol-generating material may be colour-matched to other components of the aerosol-generating composition or to other components of an article comprising the aerosol-generating material.

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

The colourant may be incorporated during the formation of the aerosol generating material (e.g. when forming a slurry comprising the materials that form the aerosol-generating material) or it may be applied to the aerosol-generating material after its formation (e.g. by spraying it onto the aerosol-generating material).

As noted above, further aspects of the invention provide

- an aerosol-generating material obtainable or obtained by methods of the first aspect,

- an article for use in a non-combustible aerosol provision system, the article comprising an aerosol-generating material obtainable or obtained by methods of the first aspect, and

- a non-combustible aerosol provision system comprising the article according to the third aspect and a non-combustible aerosol provision device, the non-combustible aerosol provision device comprising an aerosol-generation device to generate aerosol from the article when the article is used with the non-combustible aerosol provision device. In some cases, the device includes a heater which is configured to heat the aerosol generating material, without burning.

Articles and assemblies incorporatinq the aeroso!-qeneratinq material

In some cases, the heater may heat, without burning, the aerosol-generating material to between 120°C and 350°C in use. In some cases, the heater may heat, without burning, aerosol-generating material to between 140°C and 250°C in use. In some cases in use, substantially all of the aerosol-generating material is less than about 4mm, 3mm, 2mm or 1 mm from the heater. In some cases, the solid is disposed between about 0.010mm and 2.0mm from the heater, suitably between about 0.02mm and 1.0mm, suitably 0.1 mm to 0.5mm. These minimum distances may, in some cases, reflect the thickness of a carrier that supports the aerosol-generating material. In some cases, a surface of the aerosol-generating material may directly abut the heater.

The heater is configured to heat not burn the aerosol-generating material. The heater may be, in some cases, an electrically resistive heater, such as a thin-film, electrically resistive heater. In other cases, the heater may comprise an induction heater or the like. The heater may be a combustible heat source or a chemical heat source which undergoes an exothermic reaction to product heat in use. The noncombustible aerosol provision system may comprise a plurality of heaters. The heater(s) may be powered by a battery.

The non-combustible aerosol provision system may additionally comprise a cooling element and/or a filter. The cooling element, if present, may act or function to cool gaseous or aerosol components. In some cases, it may act to cool gaseous components such that they condense to form an aerosol. It may also act to space the very hot parts of the apparatus from the user. The filter, if present, may comprise any suitable filter known in the art such as a cellulose acetate plug.

In some cases, the non-combustible aerosol provision system may be a heat- not-burn device. That is, it may contain a solid tobacco-containing material (and no liquid aerosol-generating composition). In some cases, the aerosol-generating material may comprise the tobacco material. A heat-not-burn device is disclosed in WO 2015/062983 A2, which is incorporated by reference in its entirety.

In some cases, the non-combustible aerosol provision system may be a hybrid system. That is, it may contain a solid aerosol-generating composition and a liquid aerosol-generating composition. In some cases, the aerosol-generating material may comprise nicotine. In some cases, the aerosol-generating material may comprise a tobacco material. In some cases, the aerosol-generating material may comprise a tobacco material and a separate nicotine source. The separate aerosol-generating materials may be heated by separate heaters, the same heater or, in one case, a downstream aerosol-generating composition may be heated by a hot aerosol which is generated from the upstream aerosol-generating composition. A hybrid device is disclosed in WO 2016/135331 A1, which is incorporated by reference in its entirety.

The article for use in a non-combustible aerosol provision system (which may be referred to herein as an aerosol generating article, a cartridge or a consumable) may be adapted for use in a THP, a hybrid device or another aerosol generating device. In some cases, the article may additionally comprise a filter and/or cooling element (which have been described above). In some cases, the article may be circumscribed by a wrapping material such as paper.

The article may additionally comprise ventilation apertures. These may be provided in the sidewall of the article. In some cases, the ventilation apertures may be provided in the filter and/or cooling element. These apertures may allow cool air to be drawn into the article during use, which can mix with the heated volatilised components thereby cooling the aerosol.

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

In some cases, the ratio of the cool air to the sum of the heated volatilised components and the cool air, known as the ventilation ratio, is at least 15%. A ventilation ratio of 15% enables the heated volatilised components to be made visible by the method described above. The visibility of the heated volatilised components enables the user to identify that the volatilised components have been generated and adds to the sensory experience of the smoking experience. In another example, the ventilation ratio is between 50% and 85% to provide additional cooling to the heated volatilised components. In some cases, the ventilation ratio may be at least 60% or 65%.

In some cases, the aerosol-generating material may be included in the article/a non-combustible aerosol provision system in sheet form. In some cases, the aerosolgenerating material may be included as a planar sheet. In some cases, the aerosolgenerating material may be included as a planar sheet, as a bunched or gathered sheet, as a crimped sheet, or as a rolled sheet (i.e. in the form of a tube). In some such cases, the aerosol-generating material may be included in an article/a noncombustible aerosol provision system as a sheet, such as a sheet circumscribing a rod of aerosol-generating composition (e.g. tobacco). In some other cases, the aerosolgenerating material may be formed as a sheet and then shredded and incorporated into the article. In some cases, the shredded sheet may be mixed with cut rag tobacco and incorporated into the article.

In some examples, the aerosol-generating material in sheet form may have a tensile strength of from around 200 N/m to around 900 N/m. In some examples, such as where the aerosol-generating material does not comprise a filler, the aerosolgenerating material may have a tensile strength of from 200 N/m to 400 N/m, or 200 N/m to 300 N/m, or about 250 N/m. Such tensile strengths may be particularly suitable for embodiments wherein the aerosol-generating material is formed as a sheet and then shredded and incorporated into an article. In some examples, such as where the aerosol-generating material comprises a filler, the aerosol-generating material may have a tensile strength of from 600 N/m to 900 N/m, or from 700 N/m to 900 N/m, or around 800 N/m. Such tensile strengths may be particularly suitable for embodiments wherein the aerosol-generating material is included in an article/a non-combustible aerosol provision system as a rolled sheet, suitably in the form of a tube.

The aerosol-generating material may comprise or be in the form of an aerosol-generating film. 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 may be 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 may be in the form of a wrapper, it may be gathered to form a gathered sheet or it may be shredded to form a shredded sheet. The shredded sheet may comprise one or more strands or strips of aerosol-generating material.

In one case, there is provided a consumable for use in a non-combustible aerosol-provision system comprising a planar support with complete coverage of the aerosol-generating material (e.g. a continuous aerosol-generating film). Figure 8 provides a schematic illustration of such a consumable, which includes a support layer 4 and an aerosol-generating material layer 2.

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.

In some cases, the discrete portions of aerosol-generating material are substantially round, cylindrical or hemispherical. In some cases, there is a grid shaped distribution of the substantially round, cylindrical or hemispherical aerosol generating material.

In some cases, there is provided a consumable for use in a non-combustible aerosol-provision system comprising a planar support with a discontinuous aerosol generating film (which comprises a plurality of discrete portions of aerosol-generating material) deposited on it.

Figure 9 provides an example of a consumable (401) wherein a discontinuous aerosol-generating film (which comprises discrete portions of aerosol-generating material (403)) are provided on the consumable. The non-combustible aerosol provision system may comprise an integrated article and heater, or may comprise a heater device into which the article is inserted in use. Referring to Figures 1 and 2, there are shown a partially cut-away section view and a perspective view of an example of an article 101. The article 101 is adapted for use with a device having a power source and a heater. The article 101 of this embodiment is particularly suitable for use with the device 1 shown in Figures 5 to 7, described below. In use, the article 101 may be removably inserted into the device shown in Figure 5 at an insertion point 20 of the device 1.

The article 101 of one example is in the form of a substantially cylindrical rod that includes a body of aerosol-generating composition 103 and a filter assembly 105 in the form of a rod. The aerosol-generating composition comprises the aerosol- generating material described herein. In some embodiments, it may be included in sheet form. In some embodiments it may be included in the form of a shredded sheet. In some embodiments, the aerosol-generating composition described herein may be incorporated in sheet form and in shredded form. The filter assembly 105 includes three segments, a cooling segment 107, a filter segment 109 and a mouth end segment 111. The article 101 has a first end 113, also known as a mouth end or a proximal end and a second end 115, also known as a distal end. The body of aerosol-generating composition 103 is located towards the distal end 115 of the article 101. In one example, the cooling segment 107 is located adjacent the body of aerosol-generating composition 103 between the body of aerosol generating composition 103 and the filter segment 109, such that the cooling segment 107 is in an abutting relationship with the aerosol-generating composition 103 and the filter segment 103. In other examples, there may be a separation between the body of aerosol-generating composition 103 and the cooling segment 107 and between the body of aerosol-generating composition 103 and the filter segment 109. The filter segment 109 is located in between the cooling segment 107 and the mouth end segment 111. The mouth end segment 111 is located towards the proximal end 113 of the article 101, adjacent the filter segment 109. In one example, the filter segment 109 is in an abutting relationship with the mouth end segment 111. In one embodiment, the total length of the filter assembly 105 is between 37mm and 45mm, more preferably, the total length of the filter assembly 105 is 41mm.

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

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

An axial end of the body of aerosol-generating composition 103 is visible at the distal end 115 of the article 101. However, in other embodiments, the distal end 115 of the article 101 may comprise an end member (not shown) covering the axial end of the body of aerosol-generating composition 103.

The body of aerosol-generating composition 103 is joined to the filter assembly 105 by annular tipping paper (not shown), which is located substantially around the circumference of the filter assembly 105 to surround the filter assembly 105 and extends partially along the length of the body of aerosol-generating composition 103. In one example, the tipping paper is made of 58GSM standard tipping base paper. In one example the tipping paper has a length of between 42mm and 50mm, suitably of 46mm.

In one example, the cooling segment 107 is an annular tube and is located around and defines an air gap within the cooling segment. The air gap provides a chamber for heated volatilised components generated from the body of aerosol generating composition 103 to flow. The cooling segment 107 is hollow to provide a chamber for aerosol accumulation yet rigid enough to withstand axial compressive forces and bending moments that might arise during manufacture and whilst the article 101 is in use during insertion into the device 1. In one example, the thickness of the wall of the cooling segment 107 is approximately 0.29mm.

The cooling segment 107 provides a physical displacement between the aerosol-generating composition 103 and the filter segment 109. The physical displacement provided by the cooling segment 107 will provide a thermal gradient across the length of the cooling segment 107. In one example the cooling segment 107 is configured to provide a temperature differential of at least 40 degrees Celsius between a heated volatilised component entering a first end of the cooling segment 107 and a heated volatilised component exiting a second end of the cooling segment 107. In one example the cooling segment 107 is configured to provide a temperature differential of at least 60°C between a heated volatilised component entering a first end of the cooling segment 107 and a heated volatilised component exiting a second end of the cooling segment 107. This temperature differential across the length of the cooling element 107 protects the temperature sensitive filter segment 109 from the high temperatures of the aerosol-generating composition 103 when it is heated by the device 1. If the physical displacement was not provided between the filter segment 109 and the body of aerosol-generating composition 103 and the heating elements of the device 1 , then the temperature sensitive filter segment may 109 become damaged in use, so it would not perform its required functions as effectively.

In one example the length of the cooling segment 107 is at least 15mm. In one example, the length of the cooling segment 107 is between 20mm and 30mm, more particularly 23mm to 27mm, more particularly 25mm to 27mm, suitably 25mm.

The cooling segment 107 is made of paper, which means that it is comprised of a material that does not generate compounds of concern, for example, toxic compounds when in use adjacent to the heater of the device 1. In one example, the cooling segment 107 is manufactured from a spirally wound paper tube which provides a hollow internal chamber yet maintains mechanical rigidity. Spirally wound paper tubes are able to meet the tight dimensional accuracy requirements of high-speed manufacturing processes with respect to tube length, outer diameter, roundness and straightness.

In another example, the cooling segment 107 is a recess created from stiff plug wrap or tipping paper. The stiff plug wrap or tipping paper is manufactured to have a rigidity that is sufficient to withstand the axial compressive forces and bending moments that might arise during manufacture and whilst the article 101 is in use during insertion into the device 1. The filter segment 109 may be formed of any filter material sufficient to remove one or more volatilised compounds from heated volatilised components from the aerosol-generating material. In one example the filter segment 109 is made of a mono acetate material, such as cellulose acetate. The filter segment 109 provides cooling and irritation-reduction from the heated volatilised components without depleting the quantity of the heated volatilised components to an unsatisfactory level for a user.

In some embodiments, a capsule (not illustrated) may be provided in filter segment 109. It may be disposed substantially centrally in the filter segment 109, both across the filter segment 109 diameter and along the filter segment 109 length. In other cases, it may be offset in one or more dimension. The capsule may in some cases, where present, contain a volatile component such as a flavourant or aerosol- former.

The density of the cellulose acetate tow material of the filter segment 109 controls the pressure drop across the filter segment 109, which in turn controls the draw resistance of the article 101. Therefore the selection of the material of the filter segment 109 is important in controlling the resistance to draw of the article 101. In addition, the filter segment performs a filtration function in the article 101.

In one example, the filter segment 109 is made of a 8Y15 grade of filter tow material, which provides a filtration effect on the heated volatilised material, whilst also reducing the size of condensed aerosol droplets which result from the heated volatilised material.

The presence of the filter segment 109 provides an insulating effect by providing further cooling to the heated volatilised components that exit the cooling segment 107. This further cooling effect reduces the contact temperature of the user’s lips on the surface of the filter segment 109.

In one example, the filter segment 109 is between 6mm to 10mm in length, suitably 8mm.

The mouth end segment 111 is an annular tube and is located around and defines an air gap within the mouth end segment 111. The air gap provides a chamber for heated volatilised components that flow from the filter segment 109. The mouth end segment 111 is hollow to provide a chamber for aerosol accumulation yet rigid enough to withstand axial compressive forces and bending moments that might arise during manufacture and whilst the article is in use during insertion into the device 1. In one example, the thickness of the wall of the mouth end segment 111 is approximately 0.29mm. In one example, the length of the mouth end segment 111 is between 6mm to 10mm, suitably 8mm.

The mouth end segment 111 may be manufactured from a spirally wound paper tube which provides a hollow internal chamber yet maintains critical mechanical rigidity. Spirally wound paper tubes are able to meet the tight dimensional accuracy requirements of high-speed manufacturing processes with respect to tube length, outer diameter, roundness and straightness.

The mouth end segment 111 provides the function of preventing any liquid condensate that accumulates at the exit of the filter segment 109 from coming into direct contact with a user.

It should be appreciated that, in one example, the mouth end segment 111 and the cooling segment 107 may be formed of a single tube and the filter segment 109 is located within that tube separating the mouth end segment 111 and the cooling segment 107.

Referring to Figures 3 and 4, there are shown a partially cut-away section and perspective views of an example of an article 301. The reference signs shown in Figures 3 and 4 are equivalent to the reference signs shown in Figures 1 and 2, but with an increment of 200.

In the example of the article 301 shown in Figures 3 and 4, a ventilation region 317 is provided in the article 301 to enable air to flow into the interior of the article 301 from the exterior of the article 301. In one example the ventilation region 317 takes the form of one or more ventilation holes 317 formed through the outer layer of the article 301. The ventilation holes may be located in the cooling segment 307 to aid with the cooling of the article 301. In one example, the ventilation region 317 comprises one or more rows of holes, and preferably, each row of holes is arranged circumferentially around the article 301 in a cross-section that is substantially perpendicular to a longitudinal axis of the article 301.

In one example, there are between one to four rows of ventilation holes to provide ventilation for the article 301. Each row of ventilation holes may have between 12 to 36 ventilation holes 317. The ventilation holes 317 may, for example, be between 100 to 500pm in diameter. In one example, an axial separation between rows of ventilation holes 317 is between 0.25mm and 0.75mm, suitably 0.5mm.

In one example, the ventilation holes 317 are of uniform size. In another example, the ventilation holes 317 vary in size. The ventilation holes can be made using any suitable technique, for example, one or more of the following techniques: laser technology, mechanical perforation of the cooling segment 307 or pre-perforation of the cooling segment 307 before it is formed into the article 301. The ventilation holes 317 are positioned so as to provide effective cooling to the article 301.

In one example, the rows of ventilation holes 317 are located at least 11mm from the proximal end 313 of the article, suitably between 17mm and 20mm from the proximal end 313 of the article 301. The location of the ventilation holes 317 is positioned such that user does not block the ventilation holes 317 when the article 301 is in use.

Providing the rows of ventilation holes between 17mm and 20mm from the proximal end 313 of the article 301 enables the ventilation holes 317 to be located outside of the device 1 , when the article 301 is fully inserted in the device 1 , as can be seen in Figures 6 and 7. By locating the ventilation holes outside of the device, non- heated air is able to enter the article 301 through the ventilation holes from outside the device 1 to aid with the cooling of the article 301.

The length of the cooling segment 307 is such that the cooling segment 307 will be partially inserted into the device 1, when the article 301 is fully inserted into the device 1. The length of the cooling segment 307 provides a first function of providing a physical gap between the heater arrangement of the device 1 and the heat sensitive filter arrangement 309, and a second function of enabling the ventilation holes 317 to be located in the cooling segment, whilst also being located outside of the device 1 , when the article 301 is fully inserted into the device 1. As can be seen from Figures 6 and 7, the majority of the cooling element 307 is located within the device 1. However, there is a portion of the cooling element 307 that extends out of the device 1. It is in this portion of the cooling element 307 that extends out of the device 1 in which the ventilation holes 317 are located.

Referring now to Figures 5 to 7 in more detail, there is shown an example of a device 1 arranged to heat aerosol-generating composition to volatilise at least one component of said aerosol-generating composition, typically to form an aerosol which can be inhaled. The device 1 is a heating device which releases compounds by heating, but not burning, the aerosol-generating material.

A first end 3 is sometimes referred to herein as the mouth or proximal end 3 of the device 1 and a second end 5 is sometimes referred to herein as the distal end 5 of the device 1. The device 1 has an on/off button 7 to allow the device 1 as a whole to be switched on and off as desired by a user.

The device 1 comprises a housing 9 for locating and protecting various internal components of the device 1. In the example shown, the housing 9 comprises a unibody sleeve 11 that encompasses the perimeter of the device 1 , capped with a top panel 17 which defines generally the ‘top’ of the device 1 and a bottom panel 19 which defines generally the ‘bottom’ of the device 1. In another example the housing comprises a front panel, a rear panel and a pair of opposite side panels in addition to the top panel 17 and the bottom panel 19.

The top panel 17 and/or the bottom panel 19 may be removably fixed to the uni-body sleeve 11 , to permit easy access to the interior of the device 1 , or may be “permanently” fixed to the uni-body sleeve 11, for example to deter a user from accessing the interior of the device 1. In an example, the panels 17 and 19 are made of a plastics material, including for example glass-filled nylon formed by injection moulding, and the uni-body sleeve 11 is made of aluminium, though other materials and other manufacturing processes may be used.

The top panel 17 of the device 1 has an opening 20 at the mouth end 3 of the device 1 through which, in use, the article 101, 301 including the aerosol-generating composition may be inserted into the device 1 and removed from the device 1 by a user.

The housing 9 has located or fixed therein a heater arrangement 23, control circuitry 25 and a power source 27. In this example, the heater arrangement 23, the control circuitry 25 and the power source 27 are laterally adjacent (that is, adjacent when viewed from an end), with the control circuitry 25 being located generally between the heater arrangement 23 and the power source 27, though other locations are possible.

The control circuitry 25 may include a controller, such as a microprocessor arrangement, configured and arranged to control the heating of the aerosol-generating composition in the article 101, 301 as discussed further below. The power source 27 may be for example a battery, which may be a rechargeable battery or a non-rechargeable battery. Examples of suitable batteries include for example a lithium-ion battery, a nickel battery (such as a nickel-cadmium battery), an alkaline battery and/ or the like. The battery 27 is electrically coupled to the heater arrangement 23 to supply electrical power when required and under control of the control circuitry 25 to heat the aerosol-generating material in the article (as discussed, to volatilise the aerosol-generating material without causing the aerosol generating material to burn).

An advantage of locating the power source 27 laterally adjacent to the heater arrangement 23 is that a physically large power source 25 may be used without causing the device 1 as a whole to be unduly lengthy. As will be understood, in general a physically large power source 25 has a higher capacity (that is, the total electrical energy that can be supplied, often measured in Amp-hours or the like) and thus the battery life for the device 1 can be longer.

In one example, the heater arrangement 23 is generally in the form of a hollow cylindrical tube, having a hollow interior heating chamber 29 into which the article 101, 301 comprising the aerosol-generating material is inserted for heating in use. Different arrangements for the heater arrangement 23 are possible. For example, the heater arrangement 23 may comprise a single heating element or may be formed of plural heating elements aligned along the longitudinal axis of the heater arrangement 23. The or each heating element may be annular or tubular, or at least part-annular or part- tubular around its circumference. In an example, the or each heating element may be a thin film heater. In another example, the or each heating element may be made of a ceramics material. Examples of suitable ceramics materials include alumina and aluminium nitride and silicon nitride ceramics, which may be laminated and sintered. Other heating arrangements are possible, including for example inductive heating, infrared heater elements, which heat by emitting infrared radiation, or resistive heating elements formed by for example a resistive electrical winding.

In one particular example, the heater arrangement 23 is supported by a stainless steel support tube and comprises a polyimide heating element. The heater arrangement 23 is dimensioned so that substantially the whole of the body of aerosol generating composition 103, 303 of the article 101, 301 is inserted into the heater arrangement 23 when the article 101 , 301 is inserted into the device 1.

The or each heating element may be arranged so that selected zones of the aerosol-generating composition can be independently heated, for example in turn (over time, as discussed above) or together (simultaneously) as desired.

The heater arrangement 23 in this example is surrounded along at least part of its length by a thermal insulator 31. The insulator 31 helps to reduce heat passing from the heater arrangement 23 to the exterior of the device 1. This helps to keep down the power requirements for the heater arrangement 23 as it reduces heat losses generally. The insulator 31 also helps to keep the exterior of the device 1 cool during operation of the heater arrangement 23. In one example, the insulator 31 may be a double- walled sleeve which provides a low pressure region between the two walls of the sleeve. That is, the insulator 31 may be for example a “vacuum” tube, i.e. a tube that has been at least partially evacuated so as to minimise heat transfer by conduction and/or convection. Other arrangements for the insulator 31 are possible, including using heat insulating materials, including for example a suitable foam-type material, in addition to or instead of a double-walled sleeve.

The housing 59 may further comprises various internal support structures 37 for supporting all internal components, as well as the heating arrangement 23. The device 1 further comprises a collar 33 which extends around and projects from the opening 20 into the interior of the housing 9 and a generally tubular chamber 35 which is located between the collar 33 and one end of the vacuum sleeve 31. The chamber 35 further comprises a cooling structure 35f, which in this example, comprises a plurality of cooling fins 35f spaced apart along the outer surface of the chamber 35, and each arranged circumferentially around outer surface of the chamber 35. There is an air gap 36 between the hollow chamber 35 and the article 101, 301 when it is inserted in the device 1 over at least part of the length of the hollow chamber 35. The air gap 36 is around all of the circumference of the article 101, 301 over at least part of the cooling segment 307.

The collar 33 comprises a plurality of ridges 60 arranged circumferentially around the periphery of the opening 20 and which project into the opening 20. The ridges 60 take up space within the opening 20 such that the open span of the opening 20 at the locations of the ridges 60 is less than the open span of the opening 20 at the locations without the ridges 60. The ridges 60 are configured to engage with an article 101, 301 inserted into the device to assist in securing it within the device 1. Open spaces (not shown in the Figures) defined by adjacent pairs of ridges 60 and the article 101, 301 form ventilation paths around the exterior of the article 101, 301. These ventilation paths allow hot vapours that have escaped from the article 101 , 301 to exit the device 1 and allow cooling air to flow into the device 1 around the article 101, 301 in the air gap 36. In operation, the article 101, 301 is removably inserted into an insertion point

20 of the device 1 , as shown in Figures 5 to 7. Referring particularly to Figure 6, in one example, the body of aerosol-generating composition 103, 303, which is located towards the distal end 115, 315 of the article 101, 301, is entirely received within the heater arrangement 23 of the device 1. The proximal end 113, 313 of the article 101, 301 extends from the device 1 and acts as a mouthpiece assembly for a user.

In operation, the heater arrangement 23 will heat the article 101, 301 to volatilise at least one component of the aerosol-generating material from the body of aerosol-generating composition 103, 303. The primary flow path for the heated volatilised components from the body of aerosol-generating composition 103, 303 is axially through the article 101, 301, through the chamber inside the cooling segment 107, 307, through the filter segment 109, 309, through the mouth end segment 111, 313 to the user. In one example, the temperature of the heated volatilised components that are generated from the body of aerosol-generating composition is between 60°C and 250°C, which may be above the acceptable inhalation temperature for a user. As the heated volatilised component travels through the cooling segment 107, 307, it will cool and some volatilised components will condense on the inner surface of the cooling segment 107, 307.

In the examples of the article 301 shown in Figures 3 and 4, cool air will be able to enter the cooling segment 307 via the ventilation holes 317 formed in the cooling segment 307. This cool air will mix with the heated volatilised components to provide additional cooling to the heated volatilised components.

DEFINITIONS

The active constituent as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active constituent may for example be selected from nutraceuticals, nootropics, psychoactives. The active constituent may be naturally occurring or synthetically obtained. The active constituent 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 constituent may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical.

In one embodiment the active substance is a legally permissible recreational drug. In some embodiments, the active constituent comprises nicotine.

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

The active substance may be CBD or a derivative thereof.

Cannabinoids are a class of natural or synthetic chemical compounds which act on cannabinoid receptors (i.e., CB1 and CB2) in cells that repress neurotransmitter release in the brain. Cannabinoids may be naturally occurring (phytocannabinoids) from plants such as cannabis, from animals (endocannabinoids), or artificially manufactured (synthetic cannabinoids). Cannabis species express at least 85 different phytocannabinoids, and are divided into subclasses, including cannabigerols, cannabichromenes, cannabidiols, tetrahydrocannabinols, cannabinols and cannabinodiols, and other cannabinoids. Cannabinoids found in cannabis include, without limitation: cannabigerol (CBG), cannabichromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol (CBN), cannabinodiol (CBDL), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabinerolic acid, cannabidiolic acid (CBDA), Cannabinol propyl variant (CBNV), cannabitriol (CBO), tetrahydrocannabmolic acid (THCA), and tetrahydrocannabivarinic acid (THCV A).

The active constituent may comprise one or more cannabinoid compounds selected from the group consisting of: cannabidiol (CBD), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiolic acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabichromene (CBC), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM) and cannabielsoin (CBE), cannabicitran (CBT).

The active constituent may comprise one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD) and THC (tetrahydrocannabinol).

The active constituent may comprise cannabidiol (CBD). The active constituent may comprise nicotine and cannabidiol (CBD).

As noted herein, the active constituent may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof. As used herein, the term "botanical" includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like. Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint may be chosen from the following mint varieties: Mentha arvensis, Mentha c.v., Mentha niliaca , Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v., Mentha spicata crispa, Mentha cordi folia, Mentha longi folia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens.

In some embodiments, the botanical is selected from eucalyptus, star anise, cocoa and hemp.

In some embodiments, the botanical is selected from rooibos and fennel.

As used herein, the terms "flavour" and "flavourant" refer to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang- ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas.

The flavour may suitably comprise one or more mint-flavours suitably a mint oil from any species of the genus Mentha. The flavour may suitably comprise, consist essentially of or consist of menthol.

In some embodiments, the flavour comprises menthol, spearmint and/or peppermint. In some embodiments, the flavour comprises flavour components of cucumber, blueberry, citrus fruits and/or redberry.

In some embodiments, the flavour comprises eugenol.

In some embodiments, the flavour comprises flavour components extracted from tobacco.

In some embodiments, the flavour comprises flavour components extracted from cannabis.

In some embodiments, the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucalyptol, WS-3. As used herein, the term “aerosol-former” refers to an agent that promotes the generation of an aerosol. An aerosol-former may promote the generation of an aerosol by promoting an initial vaporisation and/or the condensation of a gas to an inhalable solid and/or liquid aerosol. Suitable aerosol-formers include, but are not limited to: a polyol such as erythritol, sorbitol, glycerol, and glycols like propylene glycol or triethylene glycol; a non-polyol such as monohydric alcohols, high boiling point hydrocarbons, acids such as lactic acid, glycerol derivatives, esters such as diacetin, triacetin, triethylene glycol diacetate, triethyl citrate or myristates including ethyl myristate and isopropyl myristate and aliphatic carboxylic acid esters such as methyl stearate, dimethyl dodecanedioate and dimethyl tetradecanedioate. The aerosol-former may suitably have a composition that does not dissolve menthol. The aerosol-former may suitably comprise, consist essentially of or consist of glycerol. In some embodiments, the aerosol-former comprises one or more polyhydric alcohols, such as propylene glycol, triethylene glycol, 1 ,3-butanediol and glycerin; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and/or aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

As used herein, the term “tobacco material” refers to any material comprising tobacco or derivatives thereof. The term “tobacco material” may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. The tobacco material may comprise one or more of ground tobacco, tobacco fibre, cut tobacco, extruded tobacco, tobacco stem, reconstituted tobacco and/or tobacco extract.

The tobacco used to produce tobacco material may be any suitable tobacco, such as single grades or blends, cut rag or whole leaf, including Virginia and/or Burley and/or Oriental. It may also be tobacco particle ‘fines’ or dust, expanded tobacco, stems, expanded stems, and other processed stem materials, such as cut rolled stems. The tobacco material may be a ground tobacco or a reconstituted tobacco material. The reconstituted tobacco material may comprise tobacco fibres, and may be formed by casting, a Fourdrinier-based paper making-type approach with back addition of tobacco extract, or by extrusion.

All percentages by weight described herein (denoted wt%) are calculated on a dry weight basis, unless explicitly stated otherwise. All weight ratios are also calculated on a dry weight basis. A weight quoted on a dry weight basis refers to the whole of the extract or slurry or material, other than the water, and may include components which by themselves are liquid at room temperature and pressure, such as glycerol. Conversely, a weight percentage quoted on a wet weight basis refers to all components, including water.

For the avoidance of doubt, where in this specification the term “comprises” is used in defining the invention or features of the invention, embodiments are also disclosed in which the invention or feature can be defined using the terms “consists essentially of’ or “consists of’ in place of “comprises”. Reference to a material “comprising” certain features means that those features are included in, contained in, or held within the material.

The above embodiments are to be understood as illustrative examples of the invention. It is to be understood that any feature described in relation to any one embodiment may be used alone, or in combination with other features described, and may also be used in combination with one or more features of any other of the embodiments, or any combination of any other of the embodiments. Furthermore, equivalents and modifications not described above may also be employed without departing from the scope of the invention, which is defined in the accompanying claims.

Claims

1. A method of forming an aerosol-generating material comprising aerosol-former, gelling agent and active or flavourant, the method comprising: (a) providing a slurry comprising the gelling agent, aerosol-former and a solvent;

(b) forming a layer of the slurry;

(c) drying the slurry; and

(d) applying the active or flavourant during and/or after the drying step (c).

2. A method of forming an aerosol-generating material comprising aerosol-former, gelling agent and active or flavourant, the method comprising:

(a) providing a slurry comprising the gelling agent and a solvent;

(b) forming a layer of the slurry; (c) drying the slurry; and

3. A method according to claim 2, wherein step (d) comprises combining the active or flavourant and the aerosol-former to form a mixture, and applying said mixture during and/or after the drying step (c).

4. A method according to claim 2, wherein step (d) comprises dissolving the active or flavourant in the aerosol-former to form a solution, and applying said solution during and/or after the drying step (c).

5. A method according to claim 1 or 2, wherein step (d) comprises dissolving the active or flavourant in a solvent such as ethanol, and applying the solution during and/or after the drying step (c).

6. A method according to any of claims 1 to 5, wherein the active or flavourant is volatile or semi-volatile.

7. A method according to any of claims 1 to 6, wherein the active or flavourant comprises ethyl isobutyrate, hexanal, isoamyl acetate, 2,3,5-trimethyl pyrazine, 6-methyl-5-hepten-2-one, isovaleric acid, benzaldehyde, isoamyl isovalerate, guaiacol, methyl cyclopentenolone, hexanoic acid, menthol, gamma- hexalactone, benzyl carbinol, acetyl pyrazine, trans-anethole, piperonal, beta- caryophyllene, beta-damascenone, phenylacetic acid, beta-ionone, veratraldehyde, vanillin, 5-propenyl guaethol, gamma-nonalactone, omega-pentadecalactone, or combinations thereof.

8. A method according to claim 6, wherein the active or flavourant is volatile.

9. A method according to any of claims 1 to 8, wherein the active or flavourant comprises ethyl isobutyrate, hexanal, isoamyl acetate, 2,3,5-trimethyl pyrazine, 6-methyl-5-hepten-2-one, isovaleric acid, benzaldehyde, isoamyl isovalerate, guaiacol, methyl cyclopentenolone, hexanoic acid, menthol, gamma- hexalactone, benzyl carbinol, acetyl pyrazine, trans-anethole, or combinations thereof.

10. A method according to any of claims 1 to 5, wherein the active or flavourant comprises menthol.

11. A method according to any of claims 1 to 5, wherein the active or flavourant comprises a constituent, derivative or extract of cannabis.

12. A method according to claim 11, wherein the active or flavourant comprises a cannabinoid.

13. A method according to claim 12, wherein the active or flavourant comprises CBD.

14. A method according to any of claims 1 to 5, wherein the active or flavourant comprises one or more terpenes or a derivative thereof.

15. A method according to claim 14, wherein the one or more terpenes or a derivative thereof is selected from linalool, limonene, beta-caryophyllene, beta- citronellol, linalyl acetate, eucalyptol, caryophyllene oxide, phytol, fenchol, nerolidol, alpha-terpineol, camphene, alpha-pinene, ocimene, alpha-bisabolol, valencene, geranyl acetate, myrcene, trans-caryophyllene, terpinolene, beta-pinene, alpha- humulene, guaiol, and combinations thereof.

16. A method according to any one of claims 1 to 15, wherein the active or flavourant is applied during the drying step (c).

17. A method according to any one of claims 1 to 15, wherein the active or flavourant is applied after the drying step (c).

18. A method according to any one of claims 1 to 17, wherein the aerosol generating material comprises 0.5-60 wt% gelling agent.

19. A method according to any one of claims 1 to 18, wherein the aerosol generating material comprises 5-80 wt% aerosol-former.

20. A method according to any one of claims 1 to 19, wherein the aerosol generating material comprises up to 60 wt% active or flavourant.

21. A method according to any one of claims 1 to 20, wherein the aerosol- former comprises one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

22. A method according to claim 21 , wherein the aerosol-former comprises glycerol ora combination of glycerol and propylene glycol.

23. A method according to any one of claims 1 to 22, wherein the gelling agent comprises one or more compounds selected from polysaccharide gelling agents, such as alginate, pectin, starch or a derivative thereof, cellulose or a derivative thereof, pullulan, carrageenan, agar and agarose; gelatin; gums, such as xanthan gum, guar gum and acacia gum; silica or silicone compounds, such as PDMS and sodium silicate; clays, such as kaolin; and polyvinyl alcohol.

24. A method according to claim 23, wherein the gelling agent is a cellulose derivative, such as hydroxyl methyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose (CMC), hydroxypropyl methylcellulose (HPMC, methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), or cellulose acetate propionate (CAP).

25. A method according to claim 24, wherein the gelling agent is CMC.

26. A method according to any of claims 1 to 25, wherein the gelling agent is not crosslinked.

27. A method according to any of claims 1 to 26, wherein the aerosol generating material comprises filler.

28. A method according to any of claims 1 to 27, wherein the active or flavourant is sprayed in step (d).

29. A method according to any of claims 1 to 28, wherein the solvent is water.

30. An aerosol-generating material, obtainable or obtained by a method according to any one of claims 1 to 29.

31. An aerosol-generating material, obtainable or obtained by a method according to claim 16, wherein the active or flavourant is dispersed throughout the aerosol-generating material

32. An aerosol-generating material, obtainable or obtained by a method according to claim 17, wherein the active or flavourant is on the surface of the aerosol generating material.

33. An aerosol-generating composition comprising the aerosol-generating material of any of claims 30 to 32.

34. An article for use within a non-combustible aerosol provision system, the article comprising the aerosol-generating composition of claim 33.

35. A non-combustible aerosol provision system comprising the article according to claim 34 and a non-combustible aerosol provision device, the noncombustible aerosol provision device comprising an aerosol-generation device configured to generate aerosol from the article when the article is used with the noncombustible aerosol provision device.