WO2023242822A1

WO2023242822A1 - Tobacco-coated sheet and consumable made therefrom

Info

Publication number: WO2023242822A1
Application number: PCT/IB2023/056280
Authority: WO
Inventors: Steven D. FLYNN; John Paul Mua; Luis Monsalud
Original assignee: Nicoventures Trading Limited
Priority date: 2022-06-17
Filing date: 2023-06-16
Publication date: 2023-12-21

Abstract

The present disclosure provides an aerosol generating material in the form of a sheet. The aerosol generating material includes one or more binding and/or foam forming agents, a filler, an aerosol former material, and a tobacco material embedded in the sheet or adhered to the surface of the sheet. Further provided are methods of preparing the aerosol generating material. The aerosol generating material can be configured for use in aerosol generating components for aerosol delivery devices. Also provided are aerosol generating components and aerosol delivery devices including the aerosol generating material. Such devices utilize electrically generated heat or combustible ignition sources to heat the aerosol generating material, providing an inhalable substance in the form of an aerosol.

Description

TOBACCO-COATED SHEET AND CONSUMABLE MADE THEREFROM

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No. 63/353,160, filed on June 17, 2022, and claims priority to U.S. Provisional Application No.63/442, 237, filed January 31, 2023, each of which is incorporated herein by reference in their entirety and for all purposes.

FIELD OF THE DISCLOSURE

The present disclosure relates to aerosol generating components comprising an aerosol generating material and methods of making the same. The present disclosure further relates to consumables for use within a combustible or non-combustible aerosol provision system, the consumables comprising the aerosol generating component, and to non-combustible and combustible aerosol provision systems.

BACKGROUND

Smoking articles such as cigarettes, cigars and the like bum tobacco during use to create tobacco smoke. Alternatives to these types of articles release an inhalable aerosol or vapor by releasing compounds from a substrate material by heating without burning. These may be referred to as non-combustible smoking articles, 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 aerosolizable material. This solid aerosolizable material 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- bum devices, tobacco heating devices or tobacco heating products (THP). Various different arrangements for volatilizing at least one component of the solid aerosolizable material are known.

As another example, there are e-cigarette / tobacco heating product hybrid devices, also known as electronic tobacco hybrid devices. These hybrid devices contain a liquid source (which may or may not contain nicotine) which is vaporized by heating to produce an inhalable vapor or aerosol. These devices additionally contain a solid aerosolizable material (which may or may not contain a tobacco material) and components of this material are entrained in the inhalable vapor or aerosol to produce the inhaled medium.

Certain such tobacco heating products and electronic tobacco hybrid devices have suffered from inconsistent performance characteristics. For example, some articles have suffered from inconsistent release of inhalable materials, inadequate loading of aerosol forming materials on substrates, or poor sensory characteristics. Accordingly, it can be desirable to provide a non-combustible smoking article that can provide the sensations of cigarette, cigar, or pipe smoking, that does so without combusting the substrate material, and that does so with advantageous performance characteristics. BRIEF SUMMARY

The present disclosure relates to aerosol generating components and aerosol delivery devices that utilize electrically generated heat or combustible ignition sources to heat an aerosol generating material in order to provide an inhalable substance in the form of an aerosol for human consumption.

Aerosol generating components in the form of a sheet have a favorable filling capacity over similar cast sheet technologies. However, previous attempts at adding tobacco character by mixing milled tobacco into a foamed slurry to prepare sheets including tobacco have negatively affected the density of the foamed sheet. It has surprisingly been found according to the present disclosure that top loading tobacco pieces onto a sheet provides the desirable tobacco character to the aerosol generating material while maintaining a desirable fill capacity. Without wishing to be bound by theory, it is believed that the addition of tobacco material onto/into the sheet may deliver better tobacco character during a smoking session as the tobacco flavor would be enhanced by direct contact of the tobacco material with the aerosol former material present in the foamed sheet. The disclosed aerosol forming materials have further desirable properties, such as 1) immobilizing the tobacco material, preventing fall out of the tobacco material from consumables comprising the disclosed aerosol forming materials, even at very low tobacco rod weights; 2) adding loft to the sheet from the foaming and deposition of irregularly shaped tobacco pieces; 3) simplification of consumable design by utilizing a single substrate material; 4) the opportunity to tune/optimize flavor and user satisfaction through selection of tobacco type; and 5) the opportunity to tune/optimize physical parameters of user devices such as pressure drop.

Accordingly, in one aspect, the disclosure provides an aerosol generating material in the form of a sheet, which may or may not be foamed, the sheet having a surface, the aerosol generating material comprising:

(i) one or more binding and/or foam forming agents;

(ii) a filler;

(iii) an aerosol former material; and

(iv) a tobacco material embedded in the sheet or adhered to the surface of the sheet.

In some embodiments, the sheet is foamed, the foamed sheet comprising one or more foam forming agents. In some embodiments, the aerosol generating material further comprises from about 1 to about 6 wt% of a foam stabilizing agent. In some embodiments, the foam stabilizing agent comprises one or more surfactants or emulsifiers. In some embodiments, the foam stabilizing agent comprises sodium lauryl sulfate, sorbitan monostearate, sorbitan monooleate, polyoxyethylene sorbitan monostearate, polyethylene glycol sorbitan monooleate, cocamidopropyl betaine, lecithin, or a combination thereof.

In some embodiments, the aerosol generating material further comprises an effervescent agent. In some embodiments, the effervescent agent comprises: calcium carbonate, sodium carbonate, sodium bicarbonate, or a combination thereof; and citric acid, tartaric acid, acetic acid, aluminium sulfate, or a combination thereof.

In some embodiments, the aerosol generating material comprises from about 5 to about 35 wt% of foam forming agent. In some embodiments, the foam forming agent comprises hydroxypropyl methylcellulose (HPMC), a gum, a modified starch, maltodextrin, or a combination thereof. In some embodiments, the foam forming agent comprises HPMC.

In some embodiments, the sheet is not foamed, and the aerosol generating material comprises one or more binding agents. In some embodiments, the one or more binding agents comprise carboxymethyl cellulose, alginate, a natural gum, or a combination thereof.

In some embodiments, the aerosol generating material comprises from about 10 to about 85 wt% of the filler. In some embodiments, the filler comprises wood pulp, microcrystalline cellulose, or a combination thereof.

In some embodiments, the aerosol generating material comprises from about 20 to about 30% by weight of the aerosol former material.

In some embodiments, the aerosol former material comprises glycerol, propylene glycol, 1,3 -propanediol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3 -butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, propylene carbonate, or a combination thereof. In some embodiments, the aerosol former material is glycerol, propylene glycol, or a combination thereof.

In some embodiments, the sheet has a density in a range from about 0.02 g/cm³ to about 0.7 g/cm³. In some embodiments, the aerosol generating material has a fill value of more than about 380 g/cm³ as determined by the formula: fill value = (bulk volume / weight) x 100; wherein the bulk volume is determined using a densimeter. In some embodiments, the aerosol generating material has a porosity of about 100 s/100 mL or more as determined using a Gurley Densometer.

In some embodiments, the tobacco material embedded in the sheet or adhered to the surface of the sheet is a particulate or fibrous tobacco. In some embodiments, the tobacco material embedded in the sheet or adhered to the surface of the sheet has a width in a range from about 1 to about 2 mm, and a length of up to about 3 mm. In some embodiments, the tobacco material embedded in the sheet or adhered to the surface of the sheet the particulate tobacco material is powdered tobacco.

In some embodiments, the aerosol generating material is in a laminated form.

In some embodiments, the aerosol generating material further comprises a top coating of a film-forming agent disposed on the surface of the sheet and coating the tobacco material embedded in the sheet or adhered to the surface of the sheet. In some embodiments, the film-forming agent is selected from the group consisting of hydroxypropyl cellulose, hydroxypropyl methylcellulose, carboxymethylcellulose, modified starches, maltodextrin, alginate, carrageenan, xanthan, gellan, gum acacia, gum tragacanth, monoglycerides, diglycerides, triethyl citrate, and combinations thereof. In some embodiments, the film-forming agent is hydroxypropyl methylcellulose. In some embodiments, the film-forming agent is a combination of hydroxypropyl cellulose, monoglycerides, diglycerides, and triethyl citrate.

In another aspect is provided an aerosol generating component comprising the aerosol generating material as disclosed herein. In some embodiments, the aerosol generating component comprises from about 10 to about 100 wt% of the aerosol generating material.

In some embodiments, the aerosol generating material is in the form of a corrugated sheet. In some embodiments, the cormgated sheet is crimped and gathered into a cylindrical rod, the aerosol generating component further comprising a wrapping material circumscribing the rod.

In some embodiments, the aerosol generating material is in the form of a shredded sheet. In some embodiments, the shredded sheet is blended with an additional tobacco material which is different in character from the tobacco material embedded in or adhered to the surface of the sheet. In some embodiments, the additional tobacco material comprises reconstituted tobacco, tobacco lamina, fine-cut tobacco, cut-rag tobacco, or a combination thereof.

In yet another aspect is provided a consumable for use in a non-combustible aerosol provision device, the consumable comprising the aerosol generating component as disclosed herein.

In a still further aspect is provided a non-combustible aerosol provision system comprising the consumable as disclosed herein and a non-combustible aerosol provision device, the non-combustible aerosol provision device comprising an aerosol generating device arranged to generate aerosol from the consumable when the consumable is used with the non-combustible aerosol provision device.

In a yet further aspect is provided a combustible aerosol provision system comprising the consumable as disclosed herein and a combustible aerosol provision device.

In another aspect is provided a method of forming an aerosol generating material in the form of a sheet having a surface, and having a tobacco material embedded in the sheet or adhered to the surface thereof, the method comprising:

(a) providing a slurry comprising:

(i) one or more binding and/or foam forming agents;

(ii) a filler;

(iii) an aerosol former material; and

(iv) a solvent;

(b) optionally, aerating the slurry to form an aerated slurry;

(c) forming a layer of the optionally aerated slurry;

(d) depositing a tobacco material on the layer of optionally aerated slurry; and

(e) drying the optionally aerated slurry layer having the tobacco material deposited thereon to form the aerosol generating material.

In some embodiments, the sheet is foamed.

In some embodiments, aerating the slurry comprises mixing the slurry under high shear conditions. In some embodiments, providing the slurry comprises mixing the slurry under high shear conditions, such that the aerating is performed as part of step (a).

In some embodiments, aerating the slurry comprises bubbling a gas through the slurry. In some embodiments, aerating the slurry comprises adding an effervescent agent to the slurry, and allowing the effervescent agent to effervesce, thereby introducing gas bubbles into the slurry.

In some embodiments, the aerosol generating material is top-coated with a film-forming agent, the method further comprising: disposing the film-forming agent on the slurry following (d), and optionally drying the disposed film-forming agent to form the top-coated aerosol generating material; or disposing the film-forming agent on the aerosol generating material following (e), and optionally drying the disposed film-forming agent to form the top-coated aerosol generating material.

In some embodiments, the film-forming agent is selected from the group consisting of hydroxypropylcellulose, hydroxypropylmethylcellulose, carboxymethylcellulose, modified starches, maltodextrin, alginate, carrageenan, xanthan, gellan, gum acacia, gum tragacanth, monoglycerides, diglycerides, triethyl citrate, and combinations thereof. In some embodiments, the film-forming agent is hydroxypropylmethylcellulose. In some embodiments, the film-forming agent is a combination of hydroxypropylcellulose, monoglycerides, diglycerides, and triethyl citrate.

In some embodiments, the aerosol generating material is in laminated form, the method further comprising: forming a second layer of the optionally aerated slurry on the layer of the optionally aerated slurry following (d) to form a layered composite; and drying the layered composite to form the aerosol generating material in laminated form.

In some embodiments, the aerosol generating material is in laminated form, the method further comprising: forming a second layer of the optionally aerated slurry on the aerosol generating material following (e) to form a layered composite; and drying the layered composite to form the aerosol generating material in laminated form.

The disclosure includes, without limitations, the following embodiments.

Embodiment 1 : An aerosol generating material in the form of a sheet, which may or may not be foamed, having a surface, the aerosol generating material comprising:

(i) one or more binding agents, one or more foam forming agents, or one or more binding agents and one or more foam forming agents;

(ii) a filler;

(iii) an aerosol former material; and

Embodiment 2: The aerosol generating material of embodiment 1, wherein the sheet is foamed, the foamed sheet comprising one or more foam forming agents.

Embodiment 3 : The aerosol generating material of embodiment 2, further comprising from about 1 to about 6 wt% of a foam stabilizing agent. Embodiment 4: The aerosol generating material of embodiment 3, wherein the foam stabilizing agent comprises one or more surfactants or emulsifiers.

Embodiment 5: The aerosol generating material of embodiment 3, wherein the foam stabilizing agent comprises sodium lauryl sulfate, sorbitan monostearate, sorbitan monooleate, polyoxyethylene sorbitan monostearate, polyethylene glycol sorbitan monooleate, cocamidopropyl betaine, lecithin, or a combination thereof.

Embodiment 6: The aerosol generating material of any one of embodiments 2-5, further comprising an effervescent agent.

Embodiment 7: The aerosol generating material of embodiment 6, wherein the effervescent agent comprises: calcium carbonate, sodium carbonate, sodium bicarbonate, or a combination thereof; and citric acid, tartaric acid, acetic acid, aluminium sulfate, or a combination thereof.

Embodiment 8: The aerosol generating material of any one of embodiments 2-7, wherein the aerosol generating material comprises from about 5 to about 35 wt% of foam forming agent.

Embodiment 9: The aerosol generating material of any one of embodiments 2-8, wherein the foam forming agent comprises hydroxypropyl methylcellulose (HPMC), a gum, a modified starch, maltodextrin, or a combination thereof.

Embodiment 10: The aerosol generating material of any one of embodiments 2-9, wherein the foam forming agent comprises HPMC.

Embodiment 11 : The aerosol generating material of embodiment 1 , wherein the sheet is not foamed, and wherein the aerosol generating material comprises one or more binding agents.

Embodiment 12: The aerosol generating material of any one of embodiments 1-11, wherein the one or more binding agents comprise carboxymethyl cellulose, alginate, a natural gum, or a combination thereof.

Embodiment 13: The aerosol generating material of any one of embodiments 1-12, wherein the aerosol generating material comprises from about 10 to about 85 wt% of the filler.

Embodiment 14: The aerosol generating material of any one of embodiments 1-13, wherein the filler comprises wood pulp, microcrystalline cellulose, or a combination thereof.

Embodiment 15: The aerosol generating material of any one of embodiments 1-14, comprising from about 20 to about 30% by weight of the aerosol former material.

Embodiment 16: The aerosol generating material of any one of embodiments 1-15, wherein the aerosol former material comprises glycerol, propylene glycol, 1,3 -propanediol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3 -butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, propylene carbonate, or a combination thereof.

Embodiment 17: The aerosol generating material of any one of embodiments 1-16, wherein the aerosol former material is glycerol, propylene glycol, or a combination thereof. Embodiment 18: The aerosol generating material of any one of embodiments 1-17, wherein the sheet has a density in a range from about 0.02 g/cm³ to about 0.7 g/cm³.

Embodiment 19: The aerosol generating material of any one of embodiments 1-19, wherein the aerosol generating material has a fill value of more than about 380 g/cm³ as determined by the formula: fill value = (bulk volume / weight) x 100; wherein the bulk volume is determined using a densimeter.

Embodiment 20: The aerosol generating material of any one of embodiments 1-19, wherein the aerosol generating material has a porosity of about 100 s/100 mL or more as determined using a Gurley Densometer.

Embodiment 21: The aerosol generating material of any one of embodiments 1-20, wherein the tobacco material is a particulate or fibrous tobacco.

Embodiment 22 : The aerosol generating material of embodiment 21 , wherein the fibrous tobacco material has a width in a range from about 1 to about 2 mm, and a length of up to about 3 mm.

Embodiment 23 : The aerosol generating material of embodiment 21, wherein the particulate tobacco material is powdered tobacco.

Embodiment 24: The aerosol generating material of any one of embodiments 1-23, wherein the aerosol generating material is in a laminated form.

Embodiment 25: The aerosol generating material of any one of embodiments 1-23, further comprising a top coating of a film-forming agent disposed on the surface of the sheet and coating the tobacco material embedded in the sheet or adhered to the surface of the sheet.

Embodiment 26: The aerosol generating material of embodiment 25, wherein the film-forming agent is selected from the group consisting of hydroxypropyl cellulose, hydroxypropyl methylcellulose, carboxymethylcellulose, modified starches, maltodextrin, alginate, carrageenan, xanthan, gellan, gum acacia, gum tragacanth, monoglycerides, diglycerides, triethyl citrate, and combinations thereof.

Embodiment 27: An aerosol generating component comprising the aerosol generating material of any one of embodiments 1-26.

Embodiment 28: The aerosol generating component of embodiment 27, comprising from about 10 to about 100 wt% of the aerosol generating material.

Embodiment 29: The aerosol generating component of embodiment 27 or 28, wherein the aerosol generating material is in the form of a corrugated sheet.

Embodiment 30: The aerosol generating component of embodiment 27 or 28, wherein the aerosol generating material is in the form of a shredded sheet.

Embodiment 31: The aerosol generating component of embodiment 30, wherein the shredded sheet is blended with an additional tobacco material which is different in character from the tobacco material embedded in or adhered to the surface of the sheet. Embodiment 32: The aerosol generating component of embodiment 31, wherein the additional tobacco material comprises reconstituted tobacco, tobacco lamina, fine-cut tobacco, cut-rag tobacco, or a combination thereof.

Embodiment 33 : The aerosol generating component of embodiment 29, wherein the corrugated sheet is crimped and gathered into a cylindrical rod, the aerosol generating component further comprising a wrapping material circumscribing the rod.

Embodiment 34: A consumable for use in a non-combustible aerosol provision device, the consumable comprising the aerosol generating component of any one of embodiments 27-33.

Embodiment 35 : A non-combustible aerosol provision system comprising the consumable of embodiment 33 and a non-combustible aerosol provision device, the non-combustible aerosol provision device comprising an aerosol generating device arranged to generate aerosol from the consumable when the consumable is used with the non-combustible aerosol provision device.

Embodiment 36: A combustible aerosol provision system comprising the consumable of embodiment 34 and a combustible aerosol provision device.

Embodiment 37: A method of forming an aerosol generating material in the form of a sheet having a surface, and having a tobacco material embedded in the sheet or adhered to the surface thereof, the method comprising:

(a) providing a slurry comprising:

(ii) a filler;

(iii) an aerosol former material; and

(iv) a solvent;

(b) optionally, aerating the slurry to form an aerated slurry;

(c) forming a layer of the optionally aerated slurry;

Embodiment 38: The method of embodiment 37, wherein the sheet is foamed.

Embodiment 39: The method of embodiment 37 or 38, wherein aerating the slurry comprises mixing the slurry under high shear conditions.

Embodiment 40: The method of any one of embodiments 37-39, wherein providing the slurry comprises mixing the slurry under high shear conditions, such that the aerating is performed as part of step (a).

Embodiment 41 : The method of embodiment 37 or 38, wherein aerating the slurry comprises bubbling a gas through the slurry. Embodiment 42: The method of embodiment 37 or 38, wherein aerating the slurry comprises adding an effervescent agent to the slurry, and allowing the effervescent agent to effervesce, thereby introducing gas bubbles into the slurry.

Embodiment 43 : The method of any one of embodiments 37-42, wherein the aerosol generating material is top-coated with a film-forming agent, the method further comprising: disposing the film-forming agent on the slurry following (d), and optionally drying the disposed filmforming agent to form the top-coated aerosol generating material; or disposing the film-forming agent on the aerosol generating material following (e), and optionally drying the disposed film-forming agent to form the top-coated aerosol generating material.

Embodiment 44: The method of embodiment 43, wherein the film-forming agent is selected from the group consisting of hydroxypropyl cellulose, hydroxypropyl methylcellulose, carboxymethylcellulose, modified starches, maltodextrin, alginate, carrageenan, xanthan, gellan, gum acacia, gum tragacanth, monoglycerides, diglycerides, triethyl citrate, and combinations thereof.

Embodiment 45: The method of any one of embodiments 37-42, wherein the aerosol generating material is in laminated form, the method further comprising: forming a second layer of the optionally aerated slurry on the layer of the optionally aerated slurry following (d) to form a layered composite; and drying the layered composite to form the aerosol generating material in laminated form.

Embodiment 46: The method of any one of embodiments 37-42, wherein the aerosol generating material is in laminated form, the method further comprising: forming a second layer of the optionally aerated slurry on the aerosol generating material following (e) to form a layered composite; and drying the layered composite to form the aerosol generating material in laminated form.

These and other features, aspects, and advantages of the disclosure will be apparent from a reading of the following detailed description together with the accompanying drawings, which are briefly described below. The invention includes any combination of two, three, four, or more of the above-noted embodiments as well as combinations of any two, three, four, or more features or elements set forth in this disclosure, regardless of whether such features or elements are expressly combined in a specific embodiment description herein. This disclosure is intended to be read holistically such that any separable features or elements of the disclosed invention, in any of its various aspects and embodiments, should be viewed as intended to be combinable unless the context clearly dictates otherwise. BRIEF DESCRIPTION OF THE DRAWINGS

Having thus described aspects of the disclosure in the foregoing general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale. The drawings are exemplary only and should not be construed as limiting the disclosure.

FIG. 1 is an illustration of a method of depositing tobacco material, and optionally a second sheet layer or top coating, on a cast sheet slurry according to a non-limiting embodiment of the disclosure.

FIG. 2 is an illustration showing a perspective view of a consumable according to a non-limiting embodiment of the disclosure.

FIGS. 3A to 3C are illustrations showing perspective views of aerosol generating components according to non-limiting embodiments of the disclosure.

FIG. 4 is an illustration showing a section view of an example of a consumable according to a non-limiting embodiment of the disclosure.

FIG. 5 is an illustration showing a perspective view of the article of FIG. 4.

FIG. 6 is an illustration showing a sectional elevation of a consumable according to a non-limiting embodiment of the disclosure.

FIG. 7 is an illustration showing a perspective view of the article of FIG. 6.

FIG. 8 is an illustration showing a perspective view of a non-combustible aerosol provision system according to a non-limiting embodiment of the disclosure.

FIG. 9 is an illustration showing a section view of an example of a non-combustible aerosol provision system according to a non-limiting embodiment of the disclosure.

FIG. 10 is an illustration showing a perspective view of an example of a non-combustible aerosol provision system according to a non-limiting embodiment of the disclosure.

FIG. 11 is an illustration showing a cross-section view of an example of an aerosol generating material in laminated form according to a non-limiting embodiment of the disclosure.

FIG. 12 is an illustration showing a cross-section view of an example of an aerosol generating material in top-coated form according to a non-limiting embodiment of the disclosure.

DETAILED DESCRIPTION

The present disclosure will now be described more fully hereinafter with reference to example embodiments thereof. These example embodiments are described so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Indeed, the disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in this specification and the claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Reference to "dry weight percent" or "dry weight basis" refers to weight on the basis of dry ingredients (i.e., all ingredients except water). Reference to "wet weight" refers to the weight of the mixture including water. Unless otherwise indicated, reference to "weight percent" of a material reflects the total wet weight of the material (i.e., including water).

As described hereinafter, the present disclosure generally relates to aerosol generating materials, components, and consumables, as well as methods of making the same. Further provided are combustible and noncombustible aerosol provision system comprising the aerosol generating materials, components, and consumables. The aerosol generating components comprise an aerosol generating material. The aerosol generating materials, components, and consumables described herein are capable of generating an aerosol, for example when heated, irradiated, or energized in any other way. The aerosol generating material may, for example, be in the form of a sheet which may or may not contain nicotine.

Aerosol generating material

Provided herein is an aerosol generating material. The aerosol generating material may enhance sensory (e.g., organoleptic) properties of the aerosol generating component. In particular, the aerosol that is produced by the aerosol generating material when heated or the smoke that is produced when the article is smoked may be particularly smooth. The aerosol generating material may not exhibit undesirable organoleptic properties when heated or burned. Thus, the material exhibits a smooth and neutral flavor profile when smoked and does not emit overpowering or unpleasant flavors. Without wishing to be bound by theory, it is postulated that this may be due to the aerosol generating material having a diluting effect on the aerosol or smoke that is produced.

The aerosol generating material is in the form of a sheet having a surface, and generally comprises one or more sheet binding and/or forming agents, some of which may be a foam forming agent; a filler; an aerosol former material; and a tobacco material embedded in the sheet or adhered to the surface of the sheet. Each of the components of the aerosol generating material are described further hereinbelow.

Binding and foam forming agents

The aerosol generating material as disclosed herein comprises one or more binders or foam forming agents. In some embodiments, the aerosol generating material is in the form of a foamed sheet and comprises one or foam forming agents. According to the present disclosure, it has been found that by including one or more foam forming agents, air may be incorporated into the aerosol generating material during formation of the material. That is, by including one or more foam forming agents, the aerosol generating material may be provided in the form of a foam. This results in a decrease in the density of the material compared to when no foam forming agent is present. Surprisingly, according to the present disclosure, it has been found that this decrease in density does not adversely affect the sensory experience for the user. The disclosure therefore provides an aerosol generating material having reduced density, whilst maintaining a good sensory experience. The fill value of the aerosol generating material may also be reduced by the inclusion of one or more foam forming agents.

The aerosol generating material may comprise from about 5 wt%, 6 wt%, 7 wt%, 10 wt%, 12 wt% or 15 wt% to about 18 wt%, 20 wt%, 25 wt%, 30 wt% or 35 wt% of the one or more forming agents (all calculated on a dry weight basis). In some embodiments, the aerosol generating material comprises 5-35 wt%, 5-30 wt%, 6-25 wt%, 7-20 wt% or 12-18 wt% of the one of more foaming agents (all calculated on a dry weight basis). The forming agent generally acts to trap gas (e.g., air) bubbles when the foam is formed, e.g., by aeration of the slurry.

In some embodiments, the one or more foam forming agents may comprise a gum, for example, a natural gum. As used herein, a natural gum refers to polysaccharide materials of natural origin that have binding properties, and which are also useful as a thickening or gelling agents. Representative natural gums derived from plants, which are typically water soluble to some degree, include xanthan gum, guar gum, gum arabic, ghatti gum, gum tragacanth, karaya gum, locust bean gum, gellan gum, and combinations thereof. In some embodiments, binder comprises xanthan gum, guar gum, gum Arabic, locust bean gum, gum tragacanth, or a combination thereof. In some embodiments, the one or more foam forming agents comprises or is guar gum.

In some embodiments, the one or more foam forming agents may comprise pectin, a modified starch (e.g., hydroxylated starch), maltodextrin, or a combination thereof. In some embodiments, the foam forming agent is a modified starch. One particularly suitable modified starch emulsifier is available as TEXTRA, available from National Starch and Chemical Company, Bridgewater, NJ.

In some embodiments, the one or more foam forming agents may comprise a cellulose ether (including carboxyalkyl ethers), meaning a cellulose polymer with the hydrogen of one or more hydroxyl groups in the cellulose structure replaced with an alkyl, hydroxyalkyl, or aryl group. Non-limiting examples of such cellulose derivatives include methylcellulose, hydroxypropyl cellulose ("HPC"), hydroxypropyl methylcellulose ("HPMC"), hydroxyethyl cellulose, and carboxymethylcellulose ("CMC"). Suitable cellulose ethers include hydroxypropyl cellulose, such as Klucel H from Aquaion Co.; hydroxypropyl methylcellulose, such as Methocel K4MS from DuPont; hydroxyethylcellulose, such as Natrosol 250 MRCS from Aquaion Co.; methylcellulose, such as Methocel A4M, K4M, and E15 from DuPont.; and sodium carboxymethylcellulose, such as CMC 7HF, CMC 7LF, and CMC 7H4F from Aquaion Co. In some embodiments, the one or more foam forming agents is one or more cellulose ethers (e.g., a single cellulose ether or a combination of several cellulose ethers, such as two or three, for example). In some embodiments, the one or more foam forming agents is a cellulose ether selected from the group consisting of methylcellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose, hydroxyethyl cellulose, carboxymethylcellulose, and combinations thereof. In some embodiments, the one or more foaming agents comprise, consist essentially of, or consist of HPMC.

In some embodiments, the aerosol generating material in foamed sheet form comprises a foam stabilizing agent. The foam stabilizing agent can reduce and even prevent breakdown of the foam after it has been formed. In some embodiments, the aerosol generating material comprises about 1 wt%, 1.5 wt% or 2 wt% to about 6 wt%, 8 wt% or 10 wt% of foam stabilizing agent (all calculated on a dry weight basis). In some embodiments, the aerosol generating material comprises 1-10 wt%, 1.5-9 wt% or 2-6 wt% of foam stabilizing agent (calculated on a dry weight basis).

The foam stabilizing agent may comprise one or more surfactants. In some embodiments, the one or more surfactants are each non-ionic, anionic, or amphoteric. In some embodiments, the foam stabilizing agent comprises sodium lauryl sulfate (SLS), Tween 60 (polyethylene glycol sorbitan monostearate), Tween 80 (polysorbate 80), Amphosol CA, Span 60 (sorbitan monosterate), Span 80 (sorbitan monooleate), lecithin, or mixtures thereof.

According to the present disclosure, it has been found that the use of a foam stabilizing agent can help formation of the foamed materials of the disclosure. In particular, the foam stabilizing agent can stabilise bubbles formed in the slurry and therefore help prevent the bubbles from collapsing when the slurry is dried. The use of a foam stabilizing agent may therefore assist with the formation of the aerosol generating materials of the disclosure.

Surprisingly, it has been found according to the present disclosure that when certain foam forming agents are used (e.g., HPMC), a foam stabilizing agent is not needed, and a stable foam can be formed even without the use of a foam stabilizing agent. Accordingly, in some embodiments, the use of a foam stabilizing agent is optional.

In some embodiments, the aerosol generating material in foamed sheet form further comprises a binder.

In some embodiments, the aerosol generating material is in the form of a sheet which is not foamed, the sheet comprising one or non-foamed binders. Suitable binders include, but are not limited to, alginates, cellulose derivatives, starches, gums, dextrans, carrageenan, and the like.

In some embodiments, the one or more binders is an alginate, such as ammonium alginate, propylene glycol alginate, potassium alginate, and sodium alginate. Alginates, and particularly high viscosity alginates, may be employed in conjunction with controlled levels of free calcium ions. In some embodiments, the aerosol generating material comprises, on a weight basis, from about 0 to about 10% of an alginate, for example, about 0%, about 1%, about 2%, about 3%, about 4% about 5%, about 6%, about 7%, about 8%, about 9%, or about 10% alginate.

In some embodiments, the one or more binders is or comprises one or more cellulose derivatives (e.g., a single cellulose derivative or a combination of several cellulose derivatives, such as two or three, for example). In some embodiments, the aerosol generating material comprises, on a weight basis, from about 0 to about 5% of the one or more cellulose derivatives, for example, about 0%, about 1%, about 2%, about 3%, about 4%, or about 5% of the one or more cellulose derivatives. It is to be understood that in embodiments where the aerosol generating material comprises more than one cellulose derivative, the stated weight basis of the one or more cellulose derivatives of from about 0% to about 5% reflects the total weight of the combination of cellulose derivatives. In some embodiments, the one or more cellulose derivatives is a chemically modified cellulose derivative. Suitable chemically modified cellulose derivatives include hydroxypropylcellulose, such as Klucel H from Aquaion Co.; hydroxypropylmethylcellulose, such as Methocel K4MS from The Dow Chemical Co.; hydroxyethylcellulose, such as Natrosol 250 MRCS from Aquaion Co.; microcrystalline cellulose, such as Avicel from FMC; methylcellulose, such as Methocel A4M from The Dow Chemical Co.; and sodium carboxymethylcellulose, such as CMC 7HF and CMC 7H4F from Hercules Inc. In some embodiments, the one or more binders is CMC.

In some embodiments, the one or more binders is a starch. In some embodiments, the aerosol generating material comprises, on a weight basis, from about 0 to about 30% of a starch, from about 0 to about 15% of a starch; or from about 20 to about 40% of a starch. In some embodiments, the aerosol generating material comprises, for example, about 0%, about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, or about 40% of a starch. Suitable starches include com starch, rice starch, and modified food starches. In some other embodiments, the binder is rice starch. In some embodiments, the one or more binders is a dextran. In some other embodiments, the binder may include a cyclodextrin.

In some embodiments, the one or more binders is a gum. Suitable gums include xanthan gum, guar gum, gum Arabic, locust bean gum, pullulan, and gum tragacanth. In some embodiments, the one or more binders is xanthan gum or pullulan. In some embodiments, the one or more binders is a carrageenan.

Filler

The aerosol generating material as disclosed herein comprises a filler. The amount of filler can vary. In some embodiments, the aerosol generating material comprises from about 10 wt%, 20 wt%, 30 wt%, 40 wt%, 50 wt% or 60 wt% to about 85 wt%, 80 wt% or 75 wt% of filler (all calculated on a dry weight basis). In some embodiments, the aerosol generating material comprises from about 10 to about 85 wt%, from about 50 to about 80 wt%, or from about 60 to about 75 wt% filler (all calculated on a dry weight basis). More than one filler may be used. In such embodiments, it is understood that reference to percent by weight of filler is intended to reflect the total amount of the combination of fillers present in the substrate.

The filler may comprise materials such as non-tobacco botanical materials, cellulosic materials, wood fibers or pulp, starches, sugars, sugar alcohols, inorganic substances, inert materials, and the like, and combinations thereof.

In some embodiments, the filler may comprise one or more inorganic filler materials, such as calcium carbonate, chitosan, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate, and suitable inorganic sorbents, such as molecular sieves. In some embodiments, the filler may comprise one or more organic filler materials such as wood pulp, cellulose and cellulose derivatives. In some embodiments, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood pulp, hemp fiber, cellulose or cellulose derivatives, such as microcrystalline cellulose (MCC), and/or nanocrystalline cellulose. Without wishing to be bound by theory, it is believed that including a fibrous filler in an aerosol generating material of the disclosure 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 component.

In some embodiments, microcrystalline cellulose is used as a filler in the aerosol generating material. In addition to functioning as a filler, the microcrystalline cellulose material used herein, in certain embodiments, can serve as a carrier, e.g., for flavorant. Microcrystalline cellulose has multiple uses, for example, as a texturizer, anti-caking agent, fat substitute, emulsifier, extender, and bulking agent, and as an excipient for direct compression, a binder, a disintegrant, an absorbent, a filler, a diluent, a lubricant, and an anti-adherent. In contrast to other cellulosic materials obtained directly from pulp, microcrystalline cellulose is a refined pulp product. Pulp is a lignocellulosic fibrous material prepared by chemically or mechanically separating cellulose fibers from wood, fiber crops, wastepaper, or rags, while microcrystalline cellulose is distinguished as a purified, partially depolymerized cellulose.

Cellulose is a naturally occurring polymer comprised of glucose units connected by a 1-4 beta glycosidic bond. Linear chains of cellulose are bundled together as microfibril in the walls of plant cells. Each microfibril defines a crystalline structure that is insoluble in water and resistant to reagents. However, microfibrils include amorphous regions with weaker internal bonding. The crystalline structure is isolated to produce microcrystalline cellulose. Microcrystalline cellulose can only be produced from alpha cellulose (also known as "chemical cellulose"), which is a highly refined, insoluble, relatively higher molecular weight cellulose from which sugars, pectin, and other soluble materials have been removed. With respect to other types of cellulose, beta cellulose is defined as a more degraded form of cellulose, with less crystalline regions. Further, gamma cellulose is defined as short-chain hemicelluloses. Thus, beta cellulose and gamma cellulose are typically removed from an input employed to produce microcrystalline cellulose.

In the production of microcrystalline cellulose, alpha cellulose can initially be shredded and then immersed in a hot bath of mineral acid to dissolve the amorphous regions of the microfibrils while leaving the microcrystalline structures intact. The microcrystalline structures can then be subjected to hydrolysis to break down long polymer chains until the degree of polymerization decreases and levels off to a desired extent. Chemicals and impurities can then be removed through water-washing followed by drying. The resulting microcrystalline cellulose can be embodied as a fine white crystallized powder in raw form. Methods for forming microcrystalline cellulose from a plant material are set forth, for example, in US Pat. Nos. 9,339,058 to Byrd, Jr. et al. and 10,774,472 to Sebastian, et al., both of which are incorporate herein by reference in their entirety. MCC materials are commercially available from suppliers such as DuPont de Nemours, Inc., Asahi Kasei Corporation, Sigachi Industries Limited, Accent Microcell Pvt. Ltd., and DFE Pharma GmbH & Co. KG. The microcrystalline cellulose may be selected from the group consisting of AVI CEL® grades PH-100, PH-102, PH-103, PH-105, PH- 112, PH-113, PH-200, PH-300, PH-302, VIVACEL® grades 101, 102, 12, 20 and EMOCEL® grades 50M and 90M, and the like, and mixtures thereof.

Microcrystalline cellulose is typically used in particulate form, and the size of the particles can vary. In certain embodiments, the microcrystalline cellulose material is in a very fine particulate form, such as particles having a D90 particle size of about 250 microns or less, such as about 170 microns or less, or about 150 microns or less. As used herein, the term "D90 particle size" means that 90% of the total particles are smaller than the given size. Particle size can be measured, for example, by laser diffraction or using a particle size analyzer.

In certain embodiments, the microcrystalline cellulose material has a relatively low bulk density, as compared to other types of cellulose materials, which is advantageous when a material with greater fill value is desired. Example ranges of bulk density for the microcrystalline cellulose material used in the present disclosure is about 0.50 g/mL or less, such as from about 0.26 to about 0.35 g/mL, or from about 0.26 to about 0.5 g/mL, as determined by measuring the volume of a known mass of powder. In some embodiments, in comparison to other cellulosic materials, microcrystalline cellulose may advantageously provide one or more of improved texture, anti-caking, and anti-sticking properties to aerosol generating materials comprising microcrystalline cellulose.

In some embodiments, the filler comprises a further cellulosic material, such as a cellulosic material derived from flax, cotton linters, kenaf, hibiscus, hemp, tobacco, sisal, rice straw, or esparto. Other suitable cellulosic materials include, but are not limited to, cereal grains (e.g., maize, oat, barley, rye, buckwheat, and the like), sugar beet (e.g., FIBREX® brand filler available from International Fiber Corporation), bran fiber, and mixtures thereof.

In some embodiments, the cellulosic material is a cellulosic pulp or regenerated cellulose comprising at least about 90% cellulose by weight, such as about 90%, about 95%, about 99%, or even 100% cellulose. By "regenerated cellulose" is meant a natural cellulose that has been converted to a soluble or dissolving cellulosic derivative, and subsequently regenerated, typically by forming a fiber through polymer spinning, or through film polymer casting, precipitation or extmsion.

In some embodiments, the cellulosic material comprises a nanocellulose material. As used herein, "nanocellulose material" refers to cellulose materials having at least one average particle size dimension in the range of about 1 nm to about 100 nm. As a non-limiting example, a suitable nanocellulose material may be a fibrous material prepared from any suitable cellulose-containing material, such as grasses (e.g., bamboo), cotton, tobacco, algae, and other plant-based materials, wherein the fiber is further refined such that a nano-fibrillated cellulose fiber is produced.

In some embodiments, the filler comprises wood or wood-derived fibers (e.g., wood pulp). In some embodiments, the filler comprises a combination of microcrystalline cellulose and wood pulp. In some embodiments, the filler is a combination of microcrystalline cellulose and wood pulp. In some embodiments, the filler comprises, consists essentially of or consists of wood pulp.

In some embodiments, the aerosol generating material comprises about 1 wt%, 5 wt%, 10 wt%, 12 wt% or 13 wt% to about 15 wt%, 17 wt% or 20 wt% of wood pulp (all calculated on a dry weight basis). In some embodiments, the aerosol generating material comprises from about 10-20 wt%, 10-15 wt% or 13-14 wt% wood pulp (all calculated on a dry weight basis).

In some embodiments, the filler comprises a non-tobacco botanical material. As used herein, the term "botanical material" or "botanical" refers to any plant material or fungal-derived material, including plant material in its natural form and plant material derived from natural plant materials, such as extracts or isolates from plant materials or treated plant materials (e.g., plant materials subjected to heat treatment, fermentation, or other treatment processes capable of altering the chemical nature of the material). For the purposes of the present disclosure, a "botanical material" includes but is not limited to "herbal materials," which refer to seed-producing plants that do not develop persistent woody tissue and are often valued for their medicinal or sensory characteristics (e.g., teas or tisanes). Reference to botanical material as "non-tobacco" is intended to exclude tobacco materials (i.e., does not include any Nicotiana species). The botanical materials used in the present disclosure may comprise, without limitation, any of the compounds and sources set forth herein, including mixtures thereof. Certain botanical materials of this type are sometimes referred to as dietary supplements, nutraceuticals, "phytochemicals" or "functional foods."

Non-limiting examples of non-tobacco botanical materials include without limitation acai berry Euterpe oleracea martius), acerola (Malpighia glabra), alfalfa, allspice, Angelica root, anise (e.g., star anise), annatto seed, apple (Malus domestica), apricot oil, bacopa monniera, basil (Ocimum basilicum), bee balm, beet root, bergamot, blackberry (Morus nigra), black cohosh, black pepper, black tea, blueberries, boldo (Peumus boldus), borage, bugleweed, cacao, calamus root, camu (Myrcaria dubia), cannabis/hemp, caraway seed, catnip, catuaba, cayenne, cayenne pepper, chaga mushroom, chamomile, cherry, chervil, chocolate, cinnamon (Cinnamomum cassia), citron grass (Cymbopogon citratus), clary sage, cloves, coconut (Cocos nucifera), coffee, comfrey leaf and root, coriander seed, cranberry, dandelion, Echinacea, elderberry, elderflower, endro (Anethum graveolens), evening primrose, eucalyptus, fennel, feverfew, garlic, ginger (Zingiber officinale), gingko biloba, ginseng, goji berries, goldenseal, grape seed, grapefruit, grapefruit rose (Citrus parodist), graviola (Annona muricata), green tea, gutu kola, hawthorn, hibiscus flower (Hibiscus sabdariffa), honeybush, jiao gulan, kava, jambu (Spilanthes oleraceae), jasmine (Jasminum officinale), juniper berry (Juniperus communis), lavender, lemon (Citrus limori), licorice, lilac, Lion's mane, maca (Lepidium meyenii), maijoram, milk thistle, mints (menthe), oolong tea, orange (Citrus sinensis), oregano, papaya, pennyroyal, peppermint (Mentha piperita), potato peel, quince, red clover, rooibos (red or green), rosehip (Rosa canina), rosemary, sage, Saint John's Wort, salvia (Salvia officinalis), savory, saw palmetto, silybum marianum, slippery elm bark, sorghum bran hi-tannin, sorghum grain hi-tannin, spearmint (Mentha spicata), spirulina, sumac bran, thyme, turmeric, uva ursi, valerian, vanilla, wild yam root, Wintergreen, withania somnifera, yacon root, yellow dock, yerba mate, and yerba santa.

In some embodiments, the filler comprises a starch, including native and modified starches. Certain starch materials may also be included in the substrate as a binder or other functional additive. "Starch" as used herein may refer to pure starch from any source, modified starch, or starch derivatives. Starch is present, typically in granular form, in almost all green plants and in various types of plant tissues and organs (e.g., seeds, leaves, rhizomes, roots, tubers, shoots, fruits, grains, and stems). Starch can vary in composition, as well as in granular shape and size. Often, starch from different sources has different chemical and physical characteristics. A specific starch can be selected for inclusion in the beads based on the ability of the starch material to impart a specific organoleptic property to the beads. Starches derived from various sources can be used. For example, major sources of starch include cereal grains (e.g., rice, wheat, and maize) and root vegetables (e.g., potatoes and cassava). Other examples of sources of starch include acorns, arrowroot, arracacha, bananas, barley, beans (e.g., favas, lentils, mung beans, peas, chickpeas), breadfruit, buckwheat, canna, chestnuts, colacasia, katakuri, kudzu, malanga, millet, oats, oca, Polynesian arrowroot, sago, sorghum, sweet potato, quinoa, rye, tapioca, taro, tobacco, water chestnuts, and yams. Suitable starches include, but are not limited to, com starch, rice starch, tapioca starch, and modified food starches. Certain starches are modified starches. A modified starch has undergone one or more structural modifications, often designed to alter its high heat properties. Some starches have been developed by genetic modifications and are considered to be "modified" starches. Other starches are obtained and subsequently modified. For example, modified starches can be starches that have been subjected to chemical reactions, such as esterification, etherification, oxidation, depolymerization (thinning) by acid catalysis or oxidation in the presence of base, bleaching, transglycosylation and depolymerization (e.g., dextrinization in the presence of a catalyst), cross-linking, enzyme treatment, acetylation, hydroxypropylation, and/or partial hydrolysis. Other starches are modified by heat treatments, such as pregelatinization, dextrinization, and/or cold-water swelling processes. Certain modified starches include monostarch phosphate, distarch glycerol, distarch phosphate esterified with sodium trimetaphosphate, phosphate distarch phosphate, acetylated distarch phosphate, starch acetate esterified with acetic anhydride, starch acetate esterified with vinyl acetate, acetylated distarch adipate, acetylated distarch glycerol, hydroxypropyl starch, hydroxypropyl distarch glycerol, and starch sodium octenyl succinate.

In some embodiments, the filler comprises a sugar. Suitable sugars include, but are not limited to, glucose, dextrose, fructose, maltose, and lactose.

In some embodiments, the filler comprises a sugar alcohol. Suitable sugar alcohols include, but are not limited to, sorbitol, mannitol, isomalt, maltitol, erythritol, and xylitol.

In some embodiments, the filler comprises an inorganic substance or inert substance, such as, but not limited to, chitosan, carbons (graphite, diamond, fullerenes, graphene), quartz, granite, diatomaceous earth, calcium carbonate, calcium phosphate, clays, crustacean and other marine shells, or combinations thereof. In some embodiments, the substrate material may comprise inorganic fibers of various types (e.g., fiber glass, metal wires/screens, etc.) and/or (organic) synthetic polymers. In some embodiments, these "fibrous" materials may be unstructured (e.g., randomly distributed like the cellulose fibers in tobacco cast sheet) or structured (e.g., a wire mesh).

Aerosol former material

The aerosol generating material as disclosed herein comprises an aerosol former material, which may also be referred to as a humectant. Suitable aerosol former materials include, but are not limited to, water, polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, terpenes, sugar alcohols, tobacco extract, and combinations thereof. In some embodiments, the aerosol former material may include water, polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, terpenes, sugar alcohols, tobacco extract, or a combination of any thereof. Each of poly hydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, terpenes, and sugar alcohols are further described herein below.

The amount of aerosol former material that is present in the aerosol generating material may vary. For example, in certain embodiments, sufficient amounts of aerosol former material are employed in order to provide for the generation of a visible mainstream aerosol that in many regards resembles the appearance of tobacco smoke. The amount of aerosol former materials present may be dependent upon factors such as the number of puffs desired per aerosol generating component. Generally, the aerosol generating material includes a relatively large percentage by weight of the aerosol former material (e.g., one or more polyhydric alcohols, such as glycerol), allowing for aerosol production from the aerosol generating material when heated. In some embodiments, the aerosol generating material comprises the aerosol former material in an amount of at least about 1% by weight, at least about 10% by weight, of at least about 15% by weight, at least about 20% by weight, at least about 25%by weight, at least about 30% by weight, at least about 35%by weight, at least about 40% by weight, at least about 45% by weight, at least about 50% by weight, at least about 55% by weight, or at least about 60% by weight, based on a total wet weight of the substrate. Example ranges of total aerosol former materials include about 15% to about 60% by weight, such as about 15% to about 55%, or about 15% to about 25%, based on the total wet weight of the aerosol generating material.

In some embodiments, the aerosol generating material comprises about 1 wt%, 5 wt%, 10 wt%, 12 wt% or 13 wt% to about 18 wt%, 20 wt%, 25 wt%, 30 wt%, 35 wt%, 45 wt%, 55 wt%, 65 wt%, 75 wt% or 80 wt% of an aerosol former material (all calculated on a dry weight basis). In some embodiments, the aerosol generating material comprises about 1-80 wt%, 1-50 wt%, 5-35 wt%, 10-25 wt%, 12-20 wt% or 13-18 wt% of an aerosol former material (all calculated on a dry weight basis.

In some embodiments, the aerosol former material comprises one or more poly hydric alcohols. Examples of poly hydric alcohols include glycerol, propylene glycol, and other glycols such as 1,3 -propanediol, diethylene glycol, and triethylene glycol. In some embodiments, the polyhydric alcohol is selected from the group consisting of glycerol, propylene glycol, 1,3 -propanediol, diethylene glycol, triethylene glycol, triacetin, and combinations thereof.

In some embodiments, the polyhydric alcohol is a mixture of glycerol and propylene glycol. The glycerol and propylene glycol may be present in various ratios, with either component predominating depending on the intended application. In some embodiments, the glycerol and propylene glycol are present in a ratio by weight of from about 3:1 to about 1 :3. In some embodiments, the glycerol and propylene glycol are present in a ratio by weightof about 3: 1, about 2: 1, about 1: 1, about 1 :2, or about 1 :3. In some embodiments, the glycerol and propylene glycol are present in a ratio of about 1 : 1 by weight.

In some embodiments, the aerosol former material comprises one or more polysorbates. Examples of polysorbates include Polysorbate 60 (polyoxyethylene (20) sorbitan monostearate, Tween 60) and Polysorbate 80 (polyoxyethylene (20) sorbitan monooleate, Tween 80). The type of polysorbate used or the combination of polysorbates used depends on the intended effect desired, as the different polysorbates offer different attributes due to molecular sizes. For example, the polysorbate molecules increase in size from polysorbate 20 to polysorbate 80. Using smaller size polysorbate molecules creates less vapor quantity but permits deeper lung penetration. This may be desirable when the user is in public where he would not want to create a large plume of "smoke" (i.e., vapor). Conversely, if a dense vapor is desired, which can convey the aromatic constituents of tobacco, larger polysorbate molecules can be employed. An additional benefit of using the polysorbate family of compounds is that the polysorbates lower the heat of vaporization of mixtures in which they are present.

In some embodiments, the aerosol former material comprises one or more sorbitan esters. Examples of sorbitan esters include sorbitan monolaurate, sorbitan monostearate (Span 60), sorbitan monooleate (Span 20), and sorbitan tristearate (Span 65). In some embodiments, the aerosol former material comprises one or more fatty acids. Fatty acids may include short-chain, long-chain, saturated, unsaturated, straight chain, or branched chain carboxylic acids. Fatty acids generally include C4 to C28 aliphatic carboxylic acids. Non-limiting examples of short- or long-chain fatty acids include butyric, propionic, valeric, oleic, linoleic, stearic, myristic, and palmitic acids.

In some embodiments, the aerosol former material comprises one or more fatty acid esters. Examples of fatty acid esters include alkyl esters, monoglycerides, diglycerides, and triglycerides. Examples of monoglycerides include monolaurin and glycerol monostearate. Examples of triglycerides include triolein, tripalmitin, tristearate, glycerol tributyrate, and glycerol trihexanoate).

In some embodiments, the aerosol former material comprises one or more waxes. Examples of waxes include carnauba, beeswax, candellila, which are known known to stabilize aerosol particles, improve palatability, or reduce throat irritation.

In some embodiments, the aerosol former material comprises one or more terpenes. As used herein, the term "terpenes" refers to hydrocarbon compounds produced by plants biosynthetically from isopentenyl pyrophosphate. Non-limiting examples of terpenes include limonene, pinene, famesene, myrcene, geraniol, fennel, and cembrene.

In some embodiments, the aerosol former material comprises one or more sugar alcohols. Examples of sugar alcohols include sorbitol, erythritol, mannitol, maltitol, isomalt, and xylitol. Sugar alcohols may also serve as flavor enhancers to certain flavor compounds, e.g., menthol and other volatiles, and generally improve on mouthfeel, tactile sensation, throat impact, and other sensory properties, of the resulting aerosol.

In some embodiments, the aerosol former material comprises glycerol, propylene glycol, 1,3 -propanediol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3 -butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, propylene carbonate, or a combination of any thereof. In some embodiments, the aerosol former material comprises, consists essentially of, or consists of glycerol.

Effervescent agent

In some embodiments, the aerosol generating material comprises an effervescent agent. According to the present disclosure, it has been found that in some embodiments, by using an effervescent agent, the slurry does not require mixing at high speed to aerate the slurry. This is particularly useful when a continuous process is used to form the aerosol generating material.

In some embodiments, the aerosol generating material comprises from about 1 wt%, 2 wt% or 4 wt% to about 7 wt%, 8 wt% or 10 wt% of an effervescent agent (all calculated on a dry weight basis). In some embodiments, the aerosol generating material comprises 1-10 wt%, 2-8 wt% or 4-7 wt% of effervescent agent (all calculated on a dry weight basis).

The effervescent agent may comprise calcium carbonate, sodium carbonate, sodium bicarbonate, citric acid, tartaric acid, lactic acid, acetic acid, aluminium sulfate or mixtures thereof. To produce effervescence, generally, a carbonate or bicarbonate and an acid are combined, resulting in the liberation of gaseous carbon dioxide which serves to aerate the aerosol generating material during preparation thereof. In some embodiments, the effervescent agent comprises calcium carbonate, sodium carbonate, sodium bicarbonate, or a combination thereof; and citric acid, tartaric acid, acetic acid, aluminium sulfate, or a combination thereof. One of skill in the art will recognize that following reaction of the carbonate and acid component, the aerosol generating material may comprise little of even none of the original effervescing agent(s), the effervescing agent(s) having reacted to form and release carbon dioxide.

Water

The moisture (e.g., water) content of the aerosol generating material may vary. For example, in some embodiments, the aerosol generating material comprises from about 0% to about 30% water. In some embodiments, the aerosol generating material is dried to remove at least a portion of the water present during preparation. In some embodiments, after drying, the aerosol generating material comprises from about from about 3 to about 21% water, based on the total weight of the substrate. In some embodiments, after drying, the aerosol generating material comprises from about 8 to about 10, or from about 12 to about 18% water, based on the total weight of the aerosol generating material. In some embodiments, after drying, the aerosol generating material comprises from about 15 to about 21% water, based on the total weight of the aerosol generating material. The water content of the aerosol generating material may, for example, be determined by Karl-Fischer-titration or Gas Chromatography with Thermal Conductivity Detector (GC-TCD).

Tobacco material

The aerosol generating material comprises a tobacco material. The tobacco material may be embedded in the sheet forming the aerosol generating material or may be adhered to the surface of the sheet forming the aerosol generating material. This "top-loading" of tobacco material to the cast foam sheet provides a three-dimensional network of the tobacco material with the cast sheet, adding depth and void volume to the sheet. The top-loaded tobacco material may be uniformly or randomly distributed on or in the sheet. For example, the tobacco material may be top-loaded in bands or other regular or irregular patterns on or in the sheet, or may be This top-loaded deposition of tobacco adds tobacco character to the aerosol generating material while retaining and/or improving the filling capacity of the sheet. This is in contrast to aerosol generating materials prepared by mixing milled tobacco directly into the foamed slurry, which was found according to the present disclosure to negatively affect the filling capacity. Further, without wishing to be bound by theory, it is believed that the addition of the tobacco material onto/into the cast sheet may deliver better tobacco character during a smoking session, as the flavor will be enhanced by leaf tobacco in direct contact with the high concentration of aerosol former in the cast sheet.

The tobacco material may comprise one or more of ground tobacco, tobacco fibers, cut tobacco, extruded tobacco, or tobacco stem. In some embodiments, the tobacco material comprises tobacco particle 'fines' or dust, expanded tobacco, stems, expanded stems, and other processed stem materials, such as cut rolled stems. In some embodiments, the tobacco material comprises a ground tobacco. In some embodiments, the tobacco material comprises or consists of lamina tobacco (such as cut rag tobacco). In some embodiments, the tobacco material is fine-cut (e.g. cut into narrow shreds). In some embodiments, the tobacco material is particulate or fibrous tobacco. In particular embodiments, the tobacco material is a fibrous tobacco material having a width in a range from about 1 to about 2 mm, and a length of up to about 3 mm. Such tobacco material may be referred to as "shorts", and typically comprises cut lamina. In other embodiments, the tobacco material is a powdered tobacco.

The tobacco material can vary in species, type, and form. Generally, the tobacco material is obtained from for a harvested plant of the Nicotiana species. Example Nicotiana species include N. tabacum, N. rustica, N. alata, N. arentsii, N. excelsior, N. forgetiana, N. glauca, N. glutinosa, N. gossei, N. kawakamii, N. knightiana, N. langsdorffi, N. otophora, N. setchelli, N. sylvestris, N. tomentosa, N. tomentosiformis, N. undulata, N. x sanderae, N. africana, N. amplexicaulis, N. benavidesii, N. bonariensis, N. debneyi, N. longiflora, N. maritina, N. megalosiphon, N. occidentalis, N. paniculata, N. plumbaginifolia, N. raimondii, N. rosulata, N. simulans, N. stocktonii, N. suaveolens, N. umbratica, N. velutina, N. wigandioides, N. acaulis, N. acuminata, N. attenuata, N. benthamiana, N. cavicola, N. clevelandii, N. cordifolia, N. corymbosa, N. fragrans, N. goodspeedii, N. linearis, N. miersii, N. nudicaulis, N. obtusifolia, N. occidentalis subsp. Hersperis, N. pauciflora, N. petunioides, N. quadrivalvis, N. repanda, N. rotundifolia, N. solanifolia, and N. spegazzinii. Various representative other types of plants from the Nicotiana species are set forth in Goodspeed, The Genus Nicotiana, (Chonica Botanica) (1954); US Pat. Nos. 4,660,577 to Sensabaugh, Jr. et al.; 5,387,416 to White et al., 7,025,066 to Lawson et al.; 7,798,153 to Lawrence, Jr. and 8,186,360 to Marshall et al.; each of which is incorporated herein by reference. Descriptions of various types of tobaccos, growing practices and harvesting practices are set forth in Tobacco Production, Chemistry and Technology, Davis et al. (Eds.) (1999), which is incorporated herein by reference.

Nicotiana species from which suitable tobacco materials can be obtained can be derived using genetic- modification or crossbreeding techniques (e.g., tobacco plants can be genetically engineered or crossbred to increase or decrease production of components, characteristics or attributes). See, for example, the types of genetic modifications of plants set forth in US Pat. Nos. 5,539,093 to Fitzmaurice et al.; 5,668,295 to Wahab et al.; 5,705,624 to Fitzmaurice et al.; 5,844,119 to Weigl; 6,730,832 to Dominguez et al.; 7,173,170 to Liu et al.; 7,208,659 to Colliver et al. and 7,230,160 to Benning et al.; US Patent Appl. Pub. No. 2006/0236434 to Conkling et al.; and PCT W02008/103935 to Nielsen et al. See, also, the types of tobaccos that are set forth in US Pat. Nos. 4,660,577 to Sensabaugh, Jr. et al.; 5,387,416 to White et al.; and 6,730,832 to Dominguez et al., each of which is incorporated herein by reference.

The Nicotiana species can, in some embodiments, be selected for the content of various compounds that are present therein. For example, plants can be selected on the basis that those plants produce relatively high quantities of one or more of the compounds desired to be isolated therefrom. In certain embodiments, plants of the Nicotiana species (e.g., Galpao commun tobacco) are specifically grown for their abundance of leaf surface compounds. Tobacco plants can be grown in greenhouses, growth chambers, or outdoors in fields, or grown hydroponically.

Various parts or portions of the plant of the Nicotiana species can be included within an aerosol generating material as disclosed herein. For example, virtually all of the plant (e.g., the whole plant) can be harvested, and employed as such. Alternatively, various parts or pieces of the plant can be harvested or separated for further use after harvest. For example, the flower, leaves, stem, stalk, roots, seeds, and various combinations thereof, can be isolated for further use or treatment. In some embodiments, the tobacco material comprises tobacco leaf (lamina). The aerosol generating material disclosed herein can include processed tobacco parts or pieces, cured and aged tobacco in essentially natural lamina and/or stem form. In certain embodiments, the tobacco material comprises solid tobacco material selected from the group consisting of lamina and stems. The tobacco that is used for the aerosol generating material most preferably includes tobacco lamina, or a tobacco lamina and stem mixture (of which at least a portion is smoke treated). Portions of the tobacco may have processed forms, such as processed tobacco stems (e.g., cut-rolled stems, cut-rolled-expanded stems or cut-puffed stems), or volume expanded tobacco (e.g., puffed tobacco, such as dry ice expanded tobacco (DIET)). See, for example, the tobacco expansion processes set forth in US Pat. Nos. 4,340,073 to de la Burde et al.; 5,259,403 to Guy et al.; and 5,908,032 to Poindexter, et al.; and 7,556,047 to Poindexter, et al., all of which are incorporated by reference. In addition, the aerosol generating material may incorporate tobacco that has been fermented. See, also, the types of tobacco processing techniques set forth in PCT W02005/063060 to Atchley et al., which is incorporated herein by reference.

The manner by which the tobacco material is provided in a finely divided or powder type of form may vary. Preferably, plant parts or pieces are milled, comminuted, ground or pulverized into a particulate form using equipment and techniques for grinding, milling, or the like. The plant, or parts thereof, can be subjected to external forces or pressure (e.g., by being pressed or subjected to roll treatment). When carrying out such processing conditions, the plant or portion thereof can have a moisture content that approximates its natural moisture content (e.g., its moisture content immediately upon harvest), a moisture content achieved by adding moisture to the plant or portion thereof, or a moisture content that results from the drying of the plant or portion thereof. For example, powdered, pulverized, ground, pulped, or milled pieces of plants or portions thereof can have moisture contents of less than about 25 weight percent, often less than about 20 weight percent, and frequently less than about 15 weight percent. Most preferably, the plant material is relatively dry in form during grinding or milling, using equipment such as hammer mills, cutter heads, air control mills, or the like. For example, tobacco parts or pieces may be ground or milled when the moisture content thereof is less than about 15 weight percent or less than about 5 weight percent.

For the preparation of aerosol generating materials, it is typical for a harvested plant of the Nicotiana species to be subjected to a curing process. The tobacco materials incorporated within the aerosol generating material as disclosed herein are generally those that have been appropriately cured and/or aged. Descriptions of various types of curing processes for various types of tobaccos are set forth in Tobacco Production, Chemistry and Technology, Davis et al. (Eds.) (1999). Examples of techniques and conditions for curing flue-cured tobacco are set forth in Nestor et al., Beitrage Tabakforsch. Int, 20, 467-475 (2003) and US Pat. No. 6,895,974 to Peele, which are incorporated herein by reference. Representative techniques and conditions for air curing tobacco are set forth in US Pat. No. 7,650,892 to Groves et al.; Roton et al., Beitrage Tabakforsch. Int., 21, 305-320 (2005) and Staaf et al., Beitrage Tabakforsch. Int., 21, 321-330 (2005), which are incorporated herein by reference. Certain types of tobaccos can be subjected to alternative types of curing processes, such as fire curing or sun curing.

In certain embodiments, tobacco materials that can be employed include flue-cured or Virginia (e.g., K326), burley, sun-cured (e.g., Indian Kumool and Oriental tobaccos, including Katerini, Prelip, Komotini, Xanthi and Yambol tobaccos), Maryland, dark, dark-fired, dark air cured (e.g., Madole, Passanda, Cubano, Jatin and Bezuki tobaccos), light air cured (e.g., North Wisconsin and Galpao tobaccos), Indian air cured, Red Russian and Rustica tobaccos, as well as various other rare or specialty tobaccos and various blends of any of the foregoing tobaccos.

The tobacco material may also have a so-called "blended" form. For example, the tobacco material may include a mixture of parts or pieces of flue-cured, burley (e.g., Malawi burley tobacco) and Oriental tobaccos (e.g., as tobacco composed of, or derived from, tobacco lamina, or a mixture of tobacco lamina and tobacco stem). For example, a representative blend may incorporate about 30 to about 70 parts burley tobacco (e.g., lamina, or lamina and stem), and about 30 to about 70 parts flue cured tobacco (e.g., stem, lamina, or lamina and stem) on a dry weight basis. Other example tobacco blends incorporate about 75 parts flue-cured tobacco, about 15 parts burley tobacco, and about 10 parts Oriental tobacco; or about 65 parts flue-cured tobacco, about 25 parts burley tobacco, and about 10 parts Oriental tobacco; or about 65 parts flue-cured tobacco, about 10 parts burley tobacco, and about 25 parts Oriental tobacco; on a dry weight basis. Other example tobacco blends incorporate about 20 to about 30 parts Oriental tobacco and about 70 to about 80 parts flue-cured tobacco on a dry weight basis.

Tobacco materials used in the present disclosure can be subjected to, for example, fermentation, bleaching, and the like. If desired, the tobacco materials can be, for example, irradiated, pasteurized, or otherwise subjected to controlled heat treatment. Such treatment processes are detailed, for example, in US Pat. No. 8,061,362 to Mua et al., which is incorporated herein by reference. In certain embodiments, tobacco materials can be treated with water and an additive capable of inhibiting reaction of asparagine to form acrylamide upon heating of the tobacco material (e.g., an additive selected from the group consisting of lysine, glycine, histidine, alanine, methionine, cysteine, glutamic acid, aspartic acid, proline, phenylalanine, valine, arginine, compositions incorporating di- and trivalent cations, asparaginase, certain non-reducing saccharides, certain reducing agents, phenolic compounds, certain compounds having at least one free thiol group or functionality, oxidizing agents, oxidation catalysts, natural plant extracts (e.g., rosemary extract), and combinations thereof. See, for example, the types of treatment processes described in US Pat. Pub. Nos. 8,434,496, 8,944,072, and 8,991,403 to Chen et al., which are all incorporated herein by reference. In certain embodiments, this type of treatment is useful where the original tobacco material is subjected to heat in the processes previously described.

In some embodiments, the type of tobacco material is selected such that it is initially visually lighter in color than other tobacco materials to some degree (e.g., whitened or bleached). Tobacco pulp can be whitened in certain embodiments according to any means known in the art. For example, bleached tobacco material produced by various whitening methods using various bleaching or oxidizing agents and oxidation catalysts can be used. Example oxidizing agents include peroxides (e.g., hydrogen peroxide), chlorite salts, chlorate salts, perchlorate salts, hypochlorite salts, ozone, ammonia, potassium permanganate, and combinations thereof. Example oxidation catalysts are titanium dioxide, manganese dioxide, and combinations thereof. Processes for treating tobacco with bleaching agents are discussed, for example, in US Patent Nos. 787,611 to Daniels, Jr.; 1,086,306 to Oelenheinz; 1,437,095 to Delling; 1,757,477 to Rosenhoch; 2,122,421 to Hawkinson; 2,148,147 to Baier; 2,170,107 to Baier; 2,274,649 to Baier; 2,770,239 to Prats et al.; 3,612,065 to Rosen; 3,851,653 to Rosen; 3,889,689 to Rosen; 3,943,940 to Minami; 3,943,945 to Rosen; 4,143,666 to Rainer; 4,194,514 to Campbell; 4,366,823, 4,366,824, and 4,388,933 to Rainer et al.; 4,641,667 to Schmekel et al.; 5,713,376 to Berger; 9,339,058 to Byrd Jr. et al.; 9,420,825 to Beeson et al.; and 9,950,858 to Byrd Jr. et al.; as well as in US Pat. App. Pub. Nos. 2012/0067361 to Bjorkholm et al.; 2016/0073686 to Crooks; 2017/0020183 to Bjorkholm; and 2017/0112183 to Bjorkholm, and in PCT Publ. Appl. Nos. WO1996/031255 to Giolvas and W02018/083114 to Bjorkholm, all of which are incorporated herein by reference.

In some embodiments, the whitened tobacco material can have an ISO brightness of at least about 50%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, or at least about 80%. In some embodiments, the whitened tobacco material can have an ISO brightness in the range of about 50% to about 90%, about 55% to about 75%, or about 60% to about 70%. ISO brightness can be measured according to ISO 3688: 1999 or ISO 2470-1:2016.

In some embodiments, the whitened tobacco material can be characterized as lightened in color (e.g., "whitened") in comparison to an untreated tobacco material. White colors are often defined with reference to the International Commission on Illumination's (CIE's) chromaticity diagram. The whitened tobacco material can, in certain embodiments, be characterized as closer on the chromaticity diagram to pure white than an untreated tobacco material.

The tobacco material may be processed to remove at least a portion of the nicotine present. Suitable methods of extracting nicotine from tobacco material are known in the art. In some embodiments, the tobacco material is substantially free of nicotine. By "substantially free" is meant that only trace amounts are present in the tobacco material. For example, in certain embodiments, the tobacco material can be characterized as having less than 0.001% by weight of nicotine, or less than 0.0001%, or even 0% by weight of nicotine, calculated as the free base, and based on the total weight of the tobacco material.

Active ingredient

In some embodiments, the aerosol generating material comprises one or more active ingredients. As used herein, an "active ingredient" refers to one or more substances belonging to any of the following categories: API (active pharmaceutical substances), food additives, natural medicaments, and naturally occurring substances that can have an effect on humans. Example active ingredients include any ingredient known to impact one or more biological functions within the body, such as ingredients that furnish pharmacological activity or other direct effect in the diagnosis, cure, mitigation, treatment, or prevention of disease, or which affect the structure or any function of the body of humans (e.g., provide a stimulating action on the central nervous system, have an energizing effect, an antipyretic or analgesic action, or an otherwise useful effect on the body). In some embodiments, the active ingredient may be of the type generally referred to as dietary supplements, nutraceuticals, "phytochemicals" or "functional foods". These types of additives are sometimes defined in the art as encompassing substances typically available from naturally occurring sources (e.g., botanical materials) that provide one or more advantageous biological effects (e.g., health promotion, disease prevention, or other medicinal properties), but are not classified or regulated as drugs.

Non-limiting examples of active ingredients include those falling in the categories of synthetic organic compounds, proteins and peptides, polysaccharides and other sugars, lipids, inorganic compounds, and nucleic acid sequences, having therapeutic, prophylactic, or diagnostic activity. Non-limiting examples of active ingredients include those falling in the categories of botanical ingredients, stimulants, (e.g., caffeine and guarana), amino acids (e.g., taurine, theanine, phenylalanine, tyrosine, and tryptophan) and/or pharmaceutical, nutraceutical, and medicinal ingredients (e.g., vitamins, such as B6, B12, and C, and/or cannabinoids, such as tetrahydrocannabinol (THC) and cannabidiol (CBD)), antioxidants, and nicotine components. The particular choice of active ingredients will vary depending upon the desired flavor, texture, and desired characteristics of the particular product.

The particular percentages of active ingredients present will vary depending upon the desired characteristics of the particular product. Typically, an active ingredient or combination thereof is present in a total concentration of at least about 0.001% by weight of the aerosol generating material, such as in a range from about 0.001% to about 20%. In some embodiments, the active ingredient or combination of active ingredients is present in a concentration from about 0.1% w/w to about 10% by weight, such as, e.g., from about 0.5% w/w to about 10%, from about 1% to about 10%, from about 1% to about 5% by weight, based on the total weight of the aerosol generating material. In some embodiments, the active ingredient or combination of active ingredients is present in a concentration of from about 0.001%, about 0.01%, about 0.1% , or about 1%, up to about 20% by weight, such as, e.g., from about 0.001%, about 0.002%, about 0.003%, about 0.004%, about 0.005%, about 0.006%, about 0.007%, about 0.008%, about 0.009%, about 0.01%, about 0.02%, about 0.03%, about 0.04%, about 0.05%, about 0.06%, about 0.07%, about 0.08%, about 0.09%, about 0.1%, about 0.2%, about 0.3%, about 0.4%, about 0.5% about 0.6%, about 0.7%, about 0.8%, or about 0.9%, to about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about 10%, about 11%, about 12%, about 13%, about 14%, about 15%, about 16%, about 17%, about 18%, about 19%, or about 20% by weight, based on the total weight of the aerosol generating material. Further suitable ranges for specific active ingredients are provided herein below.

In some embodiments, the active ingredient comprises one or more non-tobacco botanicals. As used herein, the term "botanical ingredient" or "botanical" refers to any plant material or fungal-derived material, including plant material in its natural form (e.g., leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like) and plant material derived from natural plant materials, such as extracts or isolates from plant materials or treated plant materials (e.g., plant materials subjected to heat treatment, fermentation, or other treatment processes capable of altering the chemical nature of the material).

For the purposes of the present disclosure, a "botanical material" includes but is not limited to "herbal materials," which refer to seed-producing plants that do not develop persistent woody tissue and are often valued for their medicinal or sensory characteristics (e.g., teas or tisanes). The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like. Reference to botanical material as "non-tobacco" is intended to exclude tobacco materials (i.e., does not include any Nicotiana species). The botanical materials used in the present aerosol generating material may comprise, without limitation, any of the compounds and sources set forth herein, including mixtures thereof. Certain botanical materials of this type are sometimes referred to as dietary supplements, nutraceuticals, "phytochemicals" or "functional foods."

Non-limiting examples of botanical materials, many of which are associated with antioxidant characteristics, include without limitation acai berry, alfalfa, allspice, aniseed, annatto seed, apricot oil, ashwagandha, bacopa monniera, baobab, basil, bay, bee balm, beet root, bergamot, black pepper, black tea, blueberries, borage seed oil, bugleweed, cacao, calamus root, cardamom, cassis, catnip, catuaba, cayenne pepper, Centella asiatica, chaga mushroom, Chai-hu, chamomile, cherry blossom, chervil, chive, chlorophyll, dark chocolate, cilantro, cinnamon, citrus, cloves, cocoa, coffee, comfrey leaf and root, black cohosh, cordyceps, coriander, cranberry, cumin, curcumin, damiana, dandelion, Dorstenia arifolia, Dorstenia odorata, echinacea, elderflower, eucalyptus, fennel, feverfew, flax, Galphimia glauca, garlic, geranium, ginger, gingko biloba, ginseng (e.g., Panax ginseng), goji berries, goldenseal, grape seed, green tea, grapefruit, Griffonia simplicifolia, guarana, gutu kola, hawthorn, hazel, hemp, hibiscus flower, honeybush, hops, jasmine, jiaogulan, juniper, Kaempferia parviflora (Thai ginseng), kava, laurel, lavender, lemon, lemon balm, lemongrass, licorice, Lion's mane, lutein, maca, mace, maijoram, matcha, mulberry, Nardostachys chinensis, maijoram, milk thistle, mints (menthe), myrtle, nutmeg, olive, oolong tea, orange, oregano, papaya, paprika, pennyroyal, peppermint, pimento, potato peel, primrose, quercetin, red clover, resveratrol, Rhizoma gastrodiae, Rhodiola, rooibos, rooibos (red or green), rose essential oil, rosehip, rosemary, saffron, sage, clary sage, sandalwood, savory, saw palmetto, Sceletium tortuosum, Schisandra, silybum marianum, Skullcap, spearmint, Spikenard, spirulina, slippery elm bark, sorghum bran hi- tannin, sorghum grain hi-tannin, Saint John's Wort, star anise, sumac bran, tarragon, terpenes, thyme, tisanes, turmeric, Turnera aphrodisiaca, uva ursi, valerian, vanilla, Viola odorata, white mulberry, wild yam root, Wintergreen, withania somnifera, yacon root, yellow dock, yerba mate, and yerba santa,

In some embodiments, the active ingredient comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof. In some embodiments, the botanical is selected from eucalyptus, star anise, cocoa, hemp, rooibos, fennel, and combinations thereof. When present, a botanical active ingredient is typically at a concentration of from about 0.01% w/w to about 10% by weight, such as, e.g., from about 0.01% w/w, about 0.05%, about 0.1%, or about 0.5%, to about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, or about 10%, about 11%, about 12%, about 13%, about 14%, or about 15% by weight, based on the total weight of the aerosol generating material.

In some embodiments, the active ingredient comprises a nicotine component. By "nicotine component" is meant any suitable form of nicotine (e.g., free base or salt) for providing systemic absorption of at least a portion of the nicotine present. The source of the nicotine may vary, and may be naturally derived or synthetic. Most preferably, the nicotine is naturally occurring and obtained as an extract from a Nicotiana species (e.g., tobacco). The nicotine can have the enantiomeric form .S'-(-)-nicotinc. 7?-(+)-nicotine, or a mixture of S(-)-nicotine and R- (+)-nicotine. Most preferably, the nicotine is in the form of .S'-(-)-nicotinc (e.g., in a form that is virtually all S(-)- nicotine) or a racemic mixture composed primarily or predominantly of .S'-(-)-nicotinc (e.g., a mixture composed of about 95 weight parts .S'-(-)-nicotinc and about 5 weight parts 7?-(+)-nicotine). Most preferably, the nicotine is employed in virtually pure form or in an essentially pure form. Highly preferred nicotine that is employed has a purity of greater than about 95 percent, more preferably greater than about 98 percent, and most preferably greater than about 99 percent, on a weight basis.

Typically, the nicotine component is selected from the group consisting of nicotine free base and a nicotine salt. In some embodiments, nicotine is in its free base form. Nicotine may be tobacco-derived (e.g., a tobacco extract) or non-tobacco derived (e.g., synthetic or otherwise obtained). In various embodiments, the aerosol generating material may comprise a nicotine component. In various embodiments, the aerosol generating material may not comprise a nicotine component. In some embodiments, the aerosol generating material may comprise a non-tobacco -derived nicotine component.

Typically, the nicotine component (calculated as the free base) when present, is in a concentration of at least about 0.001% by weight of the aerosol generating material, such as in a range from about 0.001% to about 10%. In some embodiments, the nicotine component is present in a concentration from about 0.1% w/w to about 10% by weight, such as, e.g., from about 0.1% w/w, about 0.2%, about 0.3%, about 0.4%, about 0.5% about 0.6%, about 0.7%, about 0.8%, or about 0.9%, to about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, or about 10% by weight, calculated as the free base and based on the total weight of the aerosol generating material. In some embodiments, the nicotine component is present in a concentration from about 0.1% w/w to about 3% by weight, such as, e.g., from about 0.1% w/w to about 2.5%, from about 0.1% to about 2.0%, from about 0.1% to about 1.5%, or from about 0.1% to about 1% by weight, calculated as the free base and based on the total weight of the aerosol generating material. These ranges can also apply to other active ingredients noted herein.

In some embodiments, the aerosol generating material of the disclosure can be characterized as completely free or substantially free of nicotine components. By "substantially free of nicotine components" is meant that no nicotine has been intentionally added, beyond trace amounts that may be naturally present in e.g., a botanical material or a nicotine-free milled tobacco material. For example, certain embodiments can be characterized as having less than 0.001% by weight of nicotine, or less than 0.0001%, or even 0% by weight of nicotine, calculated as the free base.

In some embodiments, the active ingredient comprises a tobacco extract. In some cases, the aerosol generating material may comprise 5-60 wt% (calculated on a dry weight basis) of tobacco extract. In some cases, the aerosol generating material may comprise from about 5 wt%, 10 wt%, 15 wt%, 20 wt% or 25 wt% to about 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (calculated on a dry weight basis) tobacco extract. For example, the aerosol generating material may comprise 10-50 wt%, 15-40 wt% or 20-35 wt% of tobacco extract. The tobacco extract may contain nicotine at a concentration such that the aerosol generating material comprises 1 wt% 1.5 wt%, 2 wt% or 2.5 wt% to about 10 wt%, 8 wt%, 6 wt%, 5 wt%, 4.5 wt% or 4 wt% (calculated on a dry weight basis) of nicotine. In some embodiments, the aerosol generating component may comprise 1-10 wt%, 2.5- 8 wt% or 2-6 wt% nicotine. In some cases, there may be no nicotine in the aerosol generating component other than that which results from the tobacco extract.

In some embodiments, the active ingredient comprises one or more cannabinoids. As used herein, the term "cannabinoid" refers to a class of diverse natural or synthetic chemical compounds that acts on cannabinoid receptors (e.g., CB1 and CB2) in cells that alter neurotransmitter release in the brain. Cannabinoids are cyclic molecules exhibiting particular properties such as the ability to easily cross the blood-brain barrier. Cannabinoids may be naturally occurring (phytocannabinoids) from plants such as cannabis, (endocannabinoids) from animals, or artificially manufactured (synthetic cannabinoids). Cannabis species express at least 85 different phytocannabinoids, and these may be divided into subclasses, including cannabigerols, cannabichromenes, cannabidiols, tetrahydrocannabinols, cannabinols and cannabinodiols, and other cannabinoids, such as cannabigerol (CBG), cannabichromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol

(CBN) and cannabinodiol (CBDL), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabinerolic acid, cannabidiolic acid (CBD A), Cannabinol propyl variant (CBNV), cannabitriol

(CBO), tetrahydrocannabmolic acid (THCA), and tetrahydrocannabivarinic acid (THCV A).

In some embodiments, the cannabinoid is selected from the group consisting of cannabigerol (CBG), cannabichromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol (CBN) and 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), tetrahydrocannabivarinic acid (THCV A), and mixtures thereof. In some embodiments, the cannabinoid comprises at least tetrahydrocannabinol (THC). In some embodiments, the cannabinoid is tetrahydrocannabinol (THC). In some embodiments, the cannabinoid comprises at least cannabidiol (CBD). In some embodiments, the cannabinoid is cannabidiol (CBD). In some embodiments, the CBD is synthetic CBD. In some embodiments, the cannabinoid (e.g., CBD) is added to the aerosol generating material in the form of an isolate. An isolate is an extract from a plant, such as cannabis, where the active material of interest (in this case the cannabinoid, such as CBD) is present in a high degree of purity, for example greater than 95%, greater than 96%, greater than 97%, greater than 98%, or around 99% purity. In some embodiments, the cannabinoid is an isolate of CBD in a high degree of purity, and the amount of any other cannabinoid in the substrate is no greater than about 1% by weight of the substrate, such as no greater than about 0.5% by weight of the substrate, such as no greater than about 0.1% by weight of the substrate such as no greater than about 0.01% by weight of the substrate. The choice of cannabinoid and the particular percentages thereof which may be present within the disclosed substrate will vary depending upon the desired characteristics of the aerosol generating material.

In some embodiments, the cannabinoid (such as CBD) is present in the aerosol generating material in a concentration of at least about 0.001% by weight of the aerosol generating material, such as in a range from about 0.001% to about 2% by weight of the aerosol generating material. In some embodiments, the cannabinoid (such as CBD) is present in the aerosol generating material in a concentration of from about 0.1% to about 1.5% by weight, based on the total weight of the aerosol generating material. In some embodiments, the cannabinoid (such as CBD) is present in a concentration from about 0.4% to about 1.5% by weight, based on the total weight of the aerosol generating material.

Alternatively, or in addition to the cannabinoid, the active ingredient may include a cannabimimetic, which is a class of compounds derived from plants other than cannabis that have biological effects on the endocannabinoid system similar to cannabinoids. Examples include yangonin, alpha-amyrin or beta-amyrin (also classified as terpenes), cyanidin, curcumin (tumeric), catechin, quercetin, salvinorin A, N-acylethanolamines, and N-alkylamide lipids. Such compounds can be used in the same amounts and ratios noted herein for cannabinoids.

In some embodiments, the active ingredient comprises nicotine and cannabidiol (CBD). In some embodiments, the active ingredient comprises nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol). In some embodiments, the active ingredient comprises nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof.

Active ingredients suitable for use in the present disclosure can also be classified as terpenes, many of which are associated with biological effects, such as calming effects. Terpenes are understood to have the general formula of (C5H₈)_n and include monoterpenes, sesquiterpenes, and diterpenes. Terpenes can be acyclic, monocyclic or bicyclic in structure. Some terpenes provide an entourage effect when used in combination with cannabinoids or cannabimimetics. Examples include beta-caryophyllene, linalool, limonene, beta-citronellol, linalyl acetate, pinene (alpha or beta), geraniol, carvone, eucalyptol, menthone, iso-menthone, piperitone, myrcene, beta-bourbonene, and germacrene, which may be used singly or in combination. In some embodiments, the terpene is a terpene derivable from a phytocannabinoid producing plant, such as a plant from the stain of the cannabis sativa species, such as hemp. Suitable terpenes in this regard include so- called "CIO” terpenes, which are those terpenes comprising 10 carbon atoms, and so-called "C15” terpenes, which are those terpenes comprising 15 carbon atoms. In some embodiments, the active ingredient comprises more than one terpene. For example, the active ingredient may comprise one, two, three, four, five, six, seven, eight, nine, ten or more terpenes as defined herein. In some embodiments, the terpene is selected from pinene (alpha and beta), geraniol, linalool, limonene, carvone, eucalyptol, menthone, iso-menthone, piperitone, myrcene, beta-bourbonene, germacrene and mixtures thereof. Terpenes and/or cannabinoids may be present in the aerosol generating material as an active ingredient, as an aerosol former material, or as a flavoring component. The amount of terpenes and/or cannabinoids present may vary accordingly based on their intended purpose.

The active ingredient may be a component of the aerosol former material or may be impregnated or otherwise incorporated separately into the aerosol generating material. For example, the impregnation may be performed during preparation of the aerosol generating material, after formation aerosol generating material, or both.

Acid

In some embodiments, the aerosol generating material comprises 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 pymvic acid.

In some embodiments, 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.

In particular embodiments, the aerosol generating material comprises nicotine and further comprises an acid. In such embodiments, the presence of an acid may stabilise dissolved nicotine species in the slurry from which the aerosol generating component 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. The presence of the acid may also improve the flavor of the aerosol when nicotine is present. For example, the perceived harshness of the nicotine may be reduced by the presence of the acid.

Flavorant

In some embodiments, the aerosol generating material comprises a flavorant. As used herein, reference to a "flavorant" refers to compounds or components that can be aerosolized and delivered to a user and which impart a sensory experience in terms of taste and/or aroma. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas. Flavorants may be natural or synthetic, and the character of the flavors imparted thereby may be described, without limitation, as fresh, sweet, herbal, confectionary, floral, fruity, or spicy. Some examples of flavorants include, but are not limited to, aloe vera, aniseed, apple, Asian spices, bacopa monniera, basil, bay leaves, beefsteak plant, bergamot, berry, betel, blueberry, bourbon, camphene, cannabis, caraway, cardamom, carvi, cascarilla, cassia, cassis, celery, chamomile, cherry, cherry blossom, chive, cilantro, cinnamon, citrus fruits, clementine, clove, cocoa, coffee, cognac, coriander, cranberry, cucumber, cumin, curcuma, damien, dragon fruit, Drambuie, durian, elderflower, eucalyptus, eugenol, fennel, fenugreek, flax, geranium, gin, ginger, ginkgo biloba, grape, guayusa, hazel, hemp, hibiscus, honeybush, honey essence, hydrangea, Indian spices, jasmine, juniper, khat, lavender, laurel, lemon, lemongrass, lemon balm, lemon oil, lemon peel, licorice, lime, limonene, mace, Japanese white bark magnolia leaf, mango, maple, maijoram, matcha, mate, menthol, mint, myrtle, mulberry, naswar, nutmeg, olive, orange blossom, orange oil, orange skin, oregano, papaya, paprika, peach, peppermint, piment, pimento, pine, rhubarb, rooibos, rosemary, rose hip, rose oil, rum, saffron, sage, sandalwood, scotch, shisha, spearmint, strawberry, tarragon, tea such as green tea or black tea, tequila, terpenes, thyme, tobacco, tropical fruit, turmeric, valerian, vanilla, verbena, wasabi, whiskey, Wintergreen, withania somnifera, yerba mate, yerba santa, ylang-ylang, and combinations thereof.

Flavorants may further include flavor enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, and trigeminal sensates. As used herein, "trigeminal sensate" refers to a flavoring agent which has an effect on the trigeminal nerve, producing sensations including heating, cooling, tingling, and the like. Non-limiting examples of trigeminal sensate flavoring agents include capsaicin, citric acid, menthol, Sichuan buttons, erythritol, and cubebol. 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 or WS-3 ( \ -cthyl-2-isopropyl-5- methy Icy clohexanecarboxamide) .

Further non-limiting examples include flavorings and flavor packages of the type and character traditionally used for the flavoring of cigarette, cigar, and pipe tobaccos. See also, Leffingwell et al., Tobacco Flavoring for Smoking Products, R. J. Reynolds Tobacco Company (1972), which is incorporated herein by reference. Flavoring agents may comprise components such as terpenes, terpenoids, aldehydes, ketones, esters, and the like. Syrups, such as high fructose com syrup, also can be employed. Some examples of plant-derived compositions that may be suitable are disclosed in U.S. Pat. No. 9,107,453 and U.S. Pat. App. Pub. No. 2012/0152265 both to Dube et al., the disclosures of which are incorporated herein by reference in their entireties. The selection of such further components is variable based upon factors such as the sensory characteristics that are desired for the smoking article, their affinity for the substrate material, their solubility, and other physiochemical properties. The present disclosure is intended to encompass any such further components that are readily apparent to those skilled in the art of tobacco and tobacco-related or tobacco-derived products. See, e.g., Gutcho, Tobacco Flavoring Substances and Methods, Noyes Data Corp. (1972) and Leffingwell et al., Tobacco Flavoring for Smoking Products (1972), the disclosures of which are incorporated herein by reference in their entireties. It should be noted that reference to a flavorant should not be limited to any single flavorant as described above, and may, in fact, represent a combination of one or more flavorants. Additional flavorants, flavoring agents, additives, and other possible enhancing constituents are described in U.S. Pat. App. No. 15/707,461 to Phillips et al., which is incorporated herein by reference in its entirety.

In some embodiments, the flavor comprises flavor components of cucumber, blueberry, citrus fruits and/or redberry . In some embodiments, the flavor comprises eugenol. In some embodiments, the flavor comprises flavor components extracted from tobacco.

The flavorant may be a component of the aerosol former material or may be impregnated separately into the aerosol generating material. The impregnation may be performed during preparation of the aerosol generating material, after aerosol generating material formation, or both.

The quantity of flavorant present may vary, and when present, is generally less than about 30%, or less than about 20% by weight of the aerosol generating material. For example, a flavorant may be present in a quantity of from about 0.1%, about 0.5%, about 1%, or about 5%, to about 10%, about 20%, or about 30% by weight of the aerosol generating material.

Colorant

In some embodiments, the aerosol generating material comprises a colorant. The addition of a colorant may alter the visual appearance of the aerosol generating material. The presence of colorant may enhance the visual appearance of the aerosol generating material and/or an aerosol generating component comprising the substrate. By adding a colorant to the aerosol generating material, the aerosol generating material may be color matched to other portions of the aerosol generating component or to other components of an article comprising the aerosol generating material.

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

The colorant 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).

Method of forming an aerosol generating material

In another aspect is provided a method of forming as aerosol generating material in the form of a sheet having a surface and having a tobacco material embedded in the sheet or adhered to the surface thereof. The method comprises (a) providing a slurry comprising:

(i) one or more binding and/or foam forming agents;

(ii) a filler;

(iii) an aerosol former material; and

(iv) a solvent;

(b) optionally aerating the slurry to form an aerated slurry;

(c) forming a layer of the slurry;

(d) depositing a tobacco material on the layer of the slurry; and

(e) drying the slurry having the tobacco material deposited thereon to form the aerosol generating material.

Each of the foam forming agents, filler, aerosol former material, and tobacco material are as described herein above.

The amount of solvent may vary. In some embodiments, the slurry comprises from about 50 wt%, 60 wt%, 70 wt%, 80 wt% or 90 wt% of solvent. In some embodiments, the solvent is water. In embodiments where the solvent is water, the dry weight content of the slurry matches the dry weight content of the aerosol generating material.

By "aerating the slurry" is meant introducing a gas into the slurry to form a foam, which is stabilized against collapse by the presence of the foam forming agent(s). In some embodiments, the gas is air. Accordingly, in some embodiments, aerating the slurry comprises mixing the slurry under high shear conditions, such that bubbles of air are incorporated into the slurry. In some embodiments, the slurry components are mixed to form the slurry prior to aerating the slurry. In other embodiments, the slurry components are mixed under high shear conditions, such that the aerating occurs during the formation of the slurry (i.e., providing the slurry comprises mixing the slurry under high shear conditions, such that the aerating is performed as part of step (a)).

In some embodiments, aerating the slurry comprises bubbling a gas through the slurry. In some embodiments, the gas is air, nitrogen, or carbon dioxide.

In some embodiments, aerating the slurry comprises adding an effervescent agent to the slurry. As described herein above, effervescent agents, such as a mixture of a carbonate or bicarbonate and an acid, generate carbon dioxide gas when allowed to react with each other, such as may occur when added to a slurry comprising water as the solvent. At least a portion of the formed gas bubbles are then captured in the slurry by the foam forming agent to provide the aerated slurry.

The slurry layer may be formed by various techniques. For example, forming a layer of the slurry may comprise spraying, casting or extruding the slurry. In some embodiments, the slurry layer is formed by electrospraying the slurry. In some cases, the slurry layer is formed by casting the slurry. In some embodiments, the slurry is applied to a support, forming the layer of aerated slurry on the support. In some embodiments, the slurry is cast onto a belt to form the layer. The tobacco material as described herein above is then deposited onto the slurry layer. For example, the tobacco material may be applied to the top surface of the wet, slurry from a hopper positioned above the slurry layer. In particular embodiments, the slurry has been cast on a casting belt to form the slurry layer, and the tobacco material is allowed to fall from a hopper positioned above the casting belt while the casting belt is in motion, thereby evenly distributing the tobacco material on the surface of the cast layer. One non-limiting embodiment of this manner of depositing the tobacco material is provided in FIG. 1. With reference to FIG. 1, discrete particles of tobacco material of varying shape are deposited from a hopper 404 onto the cast foam sheet 400, which has been cast onto a moving belt 402, providing a randomly oriented layer of tobacco material 406 adhered to and/or embedded in the cast foam sheet 400. The size of the tobacco particles 406 in FIG. 1 has been exaggerated for the purpose of illustration.

Following the deposition of the tobacco material, the layer of slurry having the tobacco material deposited thereon is dried to remove at least a portion of the solvent (e.g., water) present in the slurry. In some embodiments, the drying removes from about 50 wt%, 60 wt%, 70 wt%, 80 wt% or 90 wt% to about 80 wt%, 90 wt% or 95 wt% of solvent (e.g., water) in the slurry. In some embodiments, drying comprises heating the slurry. In some embodiments, following the drying, the cast material thickness is reduced relative to the thickness of the wet cast material. For example, in some embodiments, the thickness of the wet slurry layer is reduced by at least about 80%, such as about 85% to 90%. For example, in one non-limiting embodiment, the slurry is cast at a thickness of about 2 mm, and the resulting dried aerosol generating material has a thickness of about 0.2 mm.

In some embodiments, the aerosol generating material may be coated or laminated so as to avoid loss of the tobacco material embedded in or adhered to the surface of the sheet during later processing (e.g., cutting). Such coating or laminating may be performed before or after drying. For example, in some embodiments, the aerosol generating material is in layered form, having the tobacco material embedded between layers of the sheet. To provide such embodiments, a second layer of slurry is cast onto an initial layer of cast sheet having tobacco material disposed thereon or adhered thereto. This second layer may be applied either before or after drying the initial cast sheet layer having the tobacco material disposed thereon or adhered thereto. The layered sheets are then dried as described above, forming a layered aerosol generating material with the tobacco material embedded therein. With further reference to FIG. 1, the second slurry is loaded into an applicator 408 configured to deposit the slurry onto the initial layer of cast sheet having tobacco material disposed thereon or adhered thereto.

In some embodiments, the aerosol generating material is in a top-coated form, wherein the tobacco material embedded in or adhered to the surface of the sheet is top-coated with a film-forming agent. Suitable filmforming agents include, but are not limited to, hydroxypropyl cellulose, hydroxypropyl methylcellulose, modified starches, maltodextrin, carboxymethylcellulose, alginate, carrageenan, xanthan, gellan, gum acacia, gum tragacanthin, monoglycerides, diglycerides, triethyl citrate, and the like including combinations thereof. In some embodiments, the film-forming agent is an alginate, such as ammonium alginate, propylene glycol alginate, potassium alginate, and sodium alginate. In some embodiments, the film-forming agent is cellulose derivative is hydroxypropyl cellulose, hydroxypropyl methylcellulose, hydroxyethyl cellulose, or sodium carboxymethylcellulose. In some embodiments, the film-forming agent is a combination of hydroxypropyl cellulose, monoglycerides, diglycerides, and triethyl citrate. Example film-forming agents are commercially available under the WALOCEL™ and TEXTURECEL™ trade names. In some embodiments, the film-forming agent is a starch such as com starch, rice starch, a modified food starch. In some embodiments, the film-forming agent is a gum such as xanthan gum, guar gum, gum Arabic, locust bean gum, pullulan, or gum tragacanth.

Such top-coated material may be formed by depositing the film-forming agent onto the sheet having tobacco material disposed thereon or adhered thereto. The depositing may be performed by any suitable method, such as spraying or flowing the film-forming agent, optionally in the form of a solution in a suitable solvent, onto the sheet, or dipping the sheet into the film-forming agent. In some embodiments, the film-forming agent is sprayed or deposited onto the sheet. With further reference to FIG. 1, the film-forming agent is loaded into an applicator 408 configured to spray or deposit the slurry onto the layer of cast sheet having tobacco material disposed thereon or adhered thereto. In embodiments where the film-forming agent is applied in a solution form, the final top-coated aerosol generating material is formed by drying the resulting layer of film-forming agent to remove at least a portion of solvent present in the solution, forming the top-coated aerosol generating material.

Properties of the aerosol generating material

The aerosol generating material is generally provided as a sheet. The aerosol generating material may be continuous. For example, in a cast foam sheet, the foam may comprise or be a continuous sheet of material. The sheet may be cut into strips, such as from about 20 to 30 cuts per inch and used as a consumable or a cigarette filler. The sheet may also be shredded to form a shredded sheet and gathered into strands or bundles which are used as a consumable or cigarette as described herein below. The sheet may be in the form of a wrapper, or it may be gathered to form a gathered sheet as described herein below.

The thickness of the aerosol generating material may vary. As used herein, the term "thickness" when used in reference to the aerosol generating material describes the shortest distance between a first surface and a second surface. In embodiments where the aerosol generating material is in the form of a sheet, the thickness of the aerosol generating material is the shortest distance between a first planar surface of the sheet and a second planar surface of the sheet which opposes the first planar surface of the sheet. In some cases, the aerosol generating material may have a thickness of about 0.015 mm to about 10 mm. Suitably, the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 5 mm, 3 mm, 2 mm, 1 mm, 0.5 mm or 0.3 mm. The aerosol generating material may comprise more than one layer, and the thickness described herein refers to the aggregate thickness of those layers. The thickness values stipulated herein are mean values for the thickness in question. In some cases, the thickness may vary by no more than 25%, 20%, 15%, 10%, 5% or 1%.

The aerosol generating material in the form of a cast foam sheet is a porous material. The density of the aerosol generating material may vary. For example, in some embodiments, the aerosol generating material has a density from about 0.02 g/cm³, 0.06 g/cm³, 0.1 g/cm³ or 0.15 g/cm³ to about 0.25 g/cm³, 0.4 g/cm³, 0.6 g/cm³ or 0.7 g/cm³. In some embodiments, the aerosol generating material has a density from 0.02-0.7 g/cm³, 0.02-0.6 g/cm³, 0.02-0.5 g/cm³, 0.02-0.4 g/cm³ or 0.1-0.3 g/cm³. The fill value of the aerosol generating material may vary. For example, in some embodiments, the aerosol generating material has a fill value of more than about 380 cm³/ 100 g, more than about 400 cm³/ 100 g or more than 420 cm³/ 100 g. The fill value may be measured using a densimeter. In one embodiment, the fill value is measured according to Method A: Approximately 70-80 g of the aerosol generating material is weighed out. The weighed aerosol generating material is then transferred to the container assembly of a densimeter and the bulk volume measured. The fill value is then calculated according to Equation 1 :

Fill value = (bulk volume / weight) x 100 (Equation 1).

The Gurley porosity of the aerosol generating material may vary. For example, in some embodiments, the aerosol generating material has a Gurley porosity of about 100 s/100 mL or more, 125 s/100 mL or more or 150 s/100 mL or more. The Gurley porosity may be measured using a Gurley Densometer. In one embodiment, the Gurley porosity is measured according to Method B: The aerosol generating material is placed between the clamping plates in a Gurley Densometer. The inner cylinder is then lowered and the time taken for 100 cc of air to flow through the material is measured.

Aerosol Generatins Component

In another aspect is provided an aerosol generating component. The aerosol generating component comprises the aerosol generating material as disclosed herein. The aerosol generating component may take any suitable form, such as a shredded sheet, a corrugated sheet, or a sheet which is crimped and gathered into a cylindrical rod. In some embodiments, the aerosol generating component comprises a crimped and gathered sheet or corrugated sheet of the aerosol generating material formed into a rod, the rod having a wrapping material circumscribing the rod. An aerosol generating component in the form of a crimped, cylindrical rod according to a non-limiting embodiment is illustrated in FIG. 2. With reference to FIG. 2, the rod 500 comprises a wrapping material 502, an outermost layer of crimped paper 504, and an inner crimped bundle 506 of the aerosol generating material.

FIGS. 3A-3C provide additional example configurations of an aerosol generating component comprising the aerosol generating material. For example, as shown in FIG. 3 A, the aerosol generating component can consist of a single layer of the aerosol generating material in corrugated sheet form, rolled into a tubular form and circumscribed by a wrapping material. Alternatively, as shown in FIG. 3B, the aerosol generating material could be used in a layered form with multiple layers stacked together and circumscribed by a wrapping material. Still further, as shown in FIG. 3C, the aerosol generating material could be used in the form of a corrugated sheet wound into coils and circumscribed by a wrapping material.

In some embodiments, the aerosol generating component further comprises an additional tobacco material (e.g., reconstituted or lamina tobacco. For avoidance of doubt, this additional tobacco material is separate and distinct from the tobacco material present in or on the cast sheet of aerosol generating material and does not form part of the aerosol generating material. Instead, this additional tobacco material is physically combined with the cast sheet having tobacco material adhered to or imbedded therein. In some embodiments, the aerosol generating component comprises from about 10 to about 100 wt% of the aerosol generating material, with the remainder of the component comprising or consisting of tobacco material. In some embodiments, the tobacco material is present in the aerosol generating component in an amount of from about 50 to 90 wt%, or about 60 to 90 wt%, or about 70 to 90 wt%, or about 80 to about 90 wt% of the aerosol generating component. In some embodiments, the aerosol generating material is present in the aerosol generating component in an amount of about 5 to 40 wt%, 5 to 30 wt%, 5 to 25 wt%, or 10 to 25 wt% or 10 to 20 wt%. In some embodiments, the aerosol generating component consists of, or consists essentially of the aerosol generating material and the tobacco material.

Any suitable form of tobacco material may be used, such as tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. The tobacco material may comprise one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stem, reconstituted tobacco and/or tobacco extract.

In some embodiments, the aerosol generating material is present as a shredded sheet which is blended with tobacco material. In some embodiments, the tobacco material is fine-cut and/or shredded, e.g., the aerosol generating material and tobacco material are in a similar form. In some embodiments, the tobacco material comprises reconstituted tobacco, tobacco lamina, fine-cut tobacco, cut-rag tobacco, or a combination thereof.

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 makingtype approach with back addition of tobacco extract, or by extmsion. In some embodiments, the tobacco material comprises or consists of lamina tobacco (such as cut rag tobacco), which provides desirable sensory characteristics. In some embodiments, the tobacco material comprises reconstituted tobacco in an amount less than about 50 wt%, 30 wt%, 10 wt%, 5 wt%, or 1 wt% by dry weight of the tobacco material. In some embodiments, the tobacco material substantially does not comprise reconstituted tobacco.

In some embodiments, the tobacco material is fine-cut (e.g. cut into narrow shreds). Fine-cut tobacco material may advantageously be blended with the aerosol generating material to provide an aerosol generating component which has an even dispersion of tobacco material and aerosol generating material throughout the aerosol generating component. Fine cut tobacco (such as cut rag tobacco) has a cut width, typically represented as CPI (cuts per inch), and refers to the width of a shred of tobacco. In some examples where the tobacco material is fine cut (e.g., where the tobacco material comprises cut rag tobacco), the cut width of the aerosol generating material is from about 90 to 110% of the cut width of the cut rag tobacco. That is, the aerosol generating material and the tobacco material have similar cut widths, or shred widths. Configuring the aerosol generating material and tobacco material to have similar cut widths allows for better blending of the aerosol generating material and tobacco material. For example, shredded aerosol generating material sheet and cut rag tobacco which have similar cut widths can be blended to provide a more homogenous aerosol generating component (e.g., better distribution of each material throughout the aerosol generating component). The tobacco material may have a length of 1-4 cm. In some embodiments, the tobacco material comprises one or more of ground tobacco, tobacco fibre, cut tobacco, extmded tobacco, tobacco stem, reconstituted tobacco and/or tobacco extract. It is possible to use a relatively large amount of lamina tobacco in the aerosol generating component and still provide an acceptable aerosol when heated by a non-combustible aerosol provision system. Lamina tobacco typically provides superior sensory characteristics. In examples, the tobacco material comprises lamina tobacco in an amount of at least about 50 wt%, 60 wt%, 70 wt%, 80 wt%, 85 wt%, 90 wt%, or 95 wt% of the tobacco material. In particular examples, the tobacco material comprises cut tobacco in an amount of at least about 50 wt%, 60 wt%, 70 wt%, 80 wt%, 85 wt%, 90 wt%, or 95 wt% of the tobacco material.

The tobacco used to produce the 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.

In some embodiments, the aerosol generating material is shredded and blended with other materials, such as a support, instead of or in addition to tobacco, to form the aerosol generating component.

In some embodiments, the aerosol generating material is top-coated or laminated. In some embodiments, the aerosol generating material is in a laminated form. In such embodiments, a layer of dried, optionally aerated slurry forms a second sheet over the over the aerosol generating material such that the tobacco material embedded between the two sheet layers. Without wishing to be bound by theory, it is believed that such a laminated form is useful in avoiding loss of adhered or embedded tobacco material in subsequent processing (e.g., cutting, shredding, forming, and the like). A non-limiting embodiment of an aerosol generating material 600 in laminated form is illustrated in FIG. 11. With reference to FIG. 11, a second sheet 606, optionally in the form of a foam sheet, is adhered to and overlying the tobacco material 604 embedded in the base sheet 602 and can be in direct contact with either the tobacco material 604 alone or both the tobacco material and the base sheet.

In some embodiments, the aerosol generating material is in a top-coated form, wherein the tobacco material embedded in or adhered to the surface of the sheet is top-coated with a film-forming agent as described herein above. Without wishing to be bound by theory, it is believed that such a top-coated form is useful in avoiding loss of adhered or embedded tobacco material in subsequent processing (e.g., cutting, shredding, forming, and the like). In some embodiments, the aerosol generating material is topcoated with a film forming agent selected from the group consisting of hydroxypropylcellulose, hydroxypropylmethylcellulose, modified starches, maltodextrin, carboxymethylcellulose, alginate, carrageenan, xanthan, gellan, gum acacia, gum tragacanth, and combinations thereof. In some embodiments, the aerosol generating material is top coated with a film forming agent selected from the group consisting of hydroxypropylcellulose, hydroxypropylmethylcellulose, and carboxymethylcellulose. In some embodiments, the film forming agent is hydroxypropylmethylcellulose. A nonlimiting embodiment of an aerosol generating material 700 in top-coated form is illustrated in FIG. 12. With reference to FIG. 12, a coating 712 is adhered to and overlying the tobacco material 710 embedded in the base sheet 708 and can be in direct contact with either the tobacco material 710 alone or both the tobacco material and the base sheet.

Support In some embodiments, the aerosol generating material as described herein may be present on or in a support to form a substrate (which in some embodiments is synonymous with the term "consumable"). In such embodiments, the support functions as a scaffold on which the aerosol generating material layer is formed, easing manufacture. The support may provide rigidity to the aerosol generating material layer, easing handling. The support may be any suitable material which can be used to support an aerosol generating material. In some embodiments, the support 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 embodiments, the support may comprise or consist of a tobacco material, such as a sheet of reconstituted tobacco. In some embodiments, the support may be formed from materials selected from metal foil, paper, cardboard, wood or combinations thereof. In some embodiments, the support comprises paper. In some embodiments, the support itself may be a laminate stmcture comprising layers of materials selected from the preceding lists. In some embodiments, the support may also function as a flavor support. For example, the support may be impregnated with a flavorant or with tobacco extract.

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

In some embodiments, the support may be magnetic. This functionality may be used to fasten the support to the assembly in use or may be used to generate particular aerosol generating material shapes. In some cases, the aerosol generating substrate may comprise one or more magnets which can be used to fasten the substrate to an induction heater in use.

In some embodiments, the support may be substantially or wholly impermeable to gas and/or aerosol. This prevents aerosol or gas passage through the support 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 an aerosol generating assembly. Thus, consumption efficiency and hygiene can be improved in some cases.

In some embodiments, the surface of the support that abuts the aerosol generating material may be porous. For example, in some embodiments, the support comprises paper. A porous support such as paper is particularly suitable for the present invention; the porous (e.g., paper) layer abuts the aerosol generating 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 support (e.g., paper) so that when the gel sets and forms cross-links, the support is partially bound into the gel. This provides a strong binding between the gel and the support (and between the dried gel and the support).

Additionally, surface roughness may contribute to the strength of bond between the aerosol generating material and the support. The paper roughness (for the surface abutting the support) 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 support 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 support 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 some particular embodiments, the support 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 embodiment, 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 embodiments, the support is formed from or comprises metal foil, such as aluminium foil. A metallic support 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 support 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 20 pm, such as from about 1 pm to about 10 pm, suitably about 5 pm.

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

Consumable

In another aspect of the disclosure is provided an article (also referred to herein as a consumable). A consumable is an article, part or all of which is intended to be consumed during use by a user. A consumable may comprise or consist of an aerosol generating component as described herein. A consumable may comprise one or more other elements, such as a filter or an aerosol modifying substance. A consumable may comprise a heating element that emits heat to cause the aerosol generating component to generate aerosol in use. The heating element may, for example, comprise combustible material, or may comprise a susceptor that is heatable by penetration with a varying magnetic field.

A susceptor is material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The heating material may be an electrically conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the heating material. The heating material may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the heating material. The heating material may be both electrically conductive and magnetic, so that the heating material is heatable by both heating mechanisms.

Induction heating is a process in which an electrically conductive object is heated by penetrating the object with a varying magnetic field. The process is described by Faraday's law of induction and Ohm's law. An induction heater may comprise an electromagnet and a device for passing a varying electrical current, such as an alternating current, through the electromagnet. When the electromagnet and the object to be heated are suitably relatively positioned so that the resultant varying magnetic field produced by the electromagnet penetrates the object, one or more eddy currents are generated inside the object. The object has a resistance to the flow of electrical currents. Therefore, when such eddy currents are generated in the object, their flow against the electrical resistance of the object causes the object to be heated. This process is called Joule, ohmic, or resistive heating.

In some embodiments, the susceptor is in the form of a closed circuit. It has been found that, when the susceptor is in the form of a closed circuit, magnetic coupling between the susceptor and the electromagnet in use is enhanced, which results in greater or improved Joule heating.

Magnetic hysteresis heating is a process in which an object made of a magnetic material is heated by penetrating the object with a varying magnetic field. A magnetic material can be considered to comprise many atomic-scale magnets, or magnetic dipoles. When a magnetic field penetrates such material, the magnetic dipoles align with the magnetic field. Therefore, when a varying magnetic field, such as an alternating magnetic field, for example as produced by an electromagnet, penetrates the magnetic material, the orientation of the magnetic dipoles changes with the varying applied magnetic field. Such magnetic dipole reorientation causes heat to be generated in the magnetic material.

When an object is both electrically conductive and magnetic, penetrating the object with a varying magnetic field can cause both Joule heating and magnetic hysteresis heating in the object. Moreover, the use of magnetic material can strengthen the magnetic field, which can intensify the Joule heating.

In each of the above processes, as heat is generated inside the object itself, rather than by an external heat source by heat conduction, a rapid temperature rise in the object and more uniform heat distribution can be achieved, particularly through selection of suitable object material and geometry, and suitable varying magnetic field magnitude and orientation relative to the object. Moreover, as induction heating and magnetic hysteresis heating do not require a physical connection to be provided between the source of the varying magnetic field and the object, design freedom and control over the heating profile may be greater, and cost may be lower.

The delivery system described herein can be implemented as a combustible aerosol provision system or a non-combustible aerosol provision system.

Combustible aerosol provision system

An aspect of the invention provides a combustible aerosol provision system where a constituent aerosol generating material of the aerosol provision system (or component thereof) is combusted or burned during use in order to facilitate delivery of at least one substance to a user. In some embodiments, the delivery system is a combustible aerosol provision system, such as a system selected from the group consisting of a cigarette, a cigarillo and a cigar.

N on-combustible aerosol provision device

An aspect of the invention provides non-combustible aerosol provision system comprising an article (i.e., an aerosol generating material, component, or consumable) as described herein and non-combustible aerosol provision device comprising a heater which is configured to heat not bum the aerosol generating article. A non- combustible aerosol provision system may also be referred to as an aerosol generating assembly. A non- combustible aerosol provision device may be referred to as an aerosol generating apparatus.

In some cases, in use, the heater may heat, without burning, the aerosol generating material to a temperature equal to or less than 350°C, such as between 120°C and 350°C. In some cases, the heater may heat, without burning, the aerosol generating component to between 140 °C and 250 °C in use, or between 220°C and 280°C. In some cases, in use, substantially all of the aerosol generating material is less than about 4 mm, 3 mm, 2 mm or 1 mm from the heater. In some cases, the material is disposed between about 0.010 mm and 2.0 mm from the heater, suitably between about 0.02 mm and 1.0 mm, suitably 0.1 mm to 0.5 mm. These minimum distances may, in some cases, reflect the thickness of a support 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 bum the aerosol generating article, and thus the aerosol generating component. The heater may be, in some cases, a thin fdm, 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 produce heat in use. The aerosol generating assembly may comprise a plurality of heaters. The heater(s) may be powered by a battery.

The aerosol generating article 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 non-combustible aerosol provision device 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 aerosol generating assembly may be a heat-not-bum device. A heat-not-bum device is disclosed in International Patent Application Publication No. WO2015/062983, which is incorporated by reference in its entirety.

In some cases, the aerosol generating assembly may be an electronic tobacco hybrid device. That is, it may contain a solid aerosol generating component and a liquid aerosol generating material. 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 components may be heated by separate heaters, the same heater or, in one case, a downstream aerosol generating material may be heated by a hot aerosol which is generated from the upstream aerosol generating component. An electronic tobacco hybrid device is disclosed in International Patent Application Publication No. WO2016/135331, which is incorporated by reference in its entirety.

The aerosol generating article (which may be referred to herein as an article, a cartridge or a consumable) may be adapted for use in a THP, an electronic tobacco 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 aerosol generating article may be circumscribed by a wrapping material such as paper.

The aerosol generating 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 volatilized components thereby cooling the aerosol.

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

In some cases, the ratio of the cool air to the sum of the heated volatilized components and the cool air, known as the ventilation ratio, is at least 15%. A ventilation ratio of 15% enables the heated volatilized components to be made visible by the method described above. The visibility of the heated volatilized components enables the user to identify that the volatilized 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 volatilized components. In some cases, the ventilation ratio may be at least 60% or 65%.

In some cases, the aerosol generating component may be included in the article/assembly in sheet form as described herein above. In some cases, the aerosol generating component may be included as a planar sheet. In some cases, the aerosol generating component 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 rod or tube), each as described herein above. In some such cases, the aerosol generating material of these embodiments may be included in an aerosol generating article/assembly as a sheet, such as a sheet circumscribing a rod of aerosol generating material (e.g. tobacco). In some other cases, the aerosol generating component 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 cases, the first and second aerosol generating materials described herein may both be formed as a sheet and then shredded and mixed together to form an aerosol generating component. Said component may then be incorporated into the article. In some cases, the shredded sheets may also be mixed with cut rag tobacco and incorporated into the article. In some embodiments, the aerosol generating material is formed as a foam on a support. The aerosol generating foam may be a continuous foam or a discontinuous foam, such as an arrangement of discrete portions of foam on a support.

Referring to FIGS. 4 and 5, there are shown a partially cut-away section view and a perspective view of an example of an aerosol generating 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 FIGS. 8 to 10, described below. In use, the article 101 may be removably inserted into the device shown in FIG. 8 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 component 103 and a filter assembly 105 in the form of a rod. The aerosol generating component 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 component 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 component 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 component 103 between the body of aerosol generating component 103 and the filter segment 109, such that the cooling segment 107 is in an abutting relationship with the aerosol generating component 103 and the filter segment 103. In other examples, there may be a separation between the body of aerosol generating component 103 and the cooling segment 107 and between the body of aerosol generating component 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 37 mm and 45 mm, more preferably, the total length of the filter assembly 105 is 41 mm.

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

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

An axial end of the body of aerosol generating component 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 component 103.

The body of aerosol generating component 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 component 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 42 mm and 50 mm, suitably of 46 mm.

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 volatilized components generated from the body of aerosol generating component 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 0.29 mm.

The cooling segment 107 provides a physical displacement between the aerosol generating component 103 and the fdter 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 volatilized component entering a first end of the cooling segment 107 and a heated volatilized 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 degrees Celsius between a heated volatilized component entering a first end of the cooling segment 107 and a heated volatilized 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 component 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 component 103 and the heating elements of the device 1, then the temperature sensitive filter segment 109 may 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 15 mm. In one example, the length of the cooling segment 107 is between 20 mm and 30 mm, more particularly 23 mm to 27 mm, more particularly 25 mm to 27 mm, suitably 25 mm.

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 volatilized compounds from heated volatilized 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 volatilized components without depleting the quantity of the heated volatilized 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 flavorant or aerosol former material.

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 an 8Y15 grade of filter tow material, which provides a filtration effect on the heated volatilized material, whilst also reducing the size of condensed aerosol droplets which result from the heated volatilized material.

The presence of the filter segment 109 provides an insulating effect by providing further cooling to the heated volatilized 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 6 mm to 10 mm 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 volatilized 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 51. In one example, the thickness of the wall of the mouth end segment 111 is approximately 0.29 mm. In one example, the length of the mouth end segment 111 is between 6 mm to 10 mm, suitably 8 mm.

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 FIGS. 6 and 7, there are shown a partially cut-away section and perspective views of an example of an article 301 having an aerosol generating component 303, filter assembly 305, a cooling segment 307, a filter segment 309, a mouth end segment 311, a proximal end 313, distal end 315, and a ventilation region 317. The reference signs shown in FIGS. 6 and 7 are equivalent to the reference signs shown in FIGS. 4 and 5, but with an increment of 200.

In the example of the article 301 shown in FIGS. 6 and 7, 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 500 pm in diameter. In one example, an axial separation between rows of ventilation holes 317 is between 0.25 mm and 0.75 mm, suitably 0.5 mm.

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 11 mm from the proximal end 313 of the article, suitably between 17 mm and 20 mm 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 17 mm and 20 mm 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 FIGS. 9 and 10. 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 ofthe 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 FIGS. 9 and 10, 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 FIGS. 8 to 10 in more detail, there is shown an example of a device 1 arranged to heat aerosol generating component to volatilise at least one component of said aerosol generating component, 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 component.

Referring to FIGS. 8 and 9, 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 unibody sleeve 11, to permit easy access to the interior of the device 1 or may be "permanently” fixed to the unibody 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 unibody 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 component 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 component 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 component in the article (as discussed, to volatilise the aerosol generating material without causing the aerosol generating component to bum).

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. Each heating element may be annular or tubular, or at least part-annular or part-tubular around its circumference. In an example, each heating element may be a thin film heater. In another example, each heating element may be made of a ceramic material. Examples of suitable ceramic 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 component 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.

Each heating element may be arranged so that selected zones of the aerosol generating material 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 comprise 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 stmcture 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 51. 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 vapors 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 FIGS. 8 to 10. Referring particularly to FIG. 9, in one example, the body of aerosol generating component 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 component from the body of aerosol generating component 103, 303.

The primary flow path for the heated volatilized materials from the body of aerosol generating component 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, 311 to the user. In one example, the temperature of the heated volatilized components that are generated from the body of aerosol generating component is between 60°C and 250°C, which may be above the acceptable inhalation temperature for a user. As the heated volatilized material travels through the cooling segment 107, 307, it will cool and some volatilized materials will condense on the inner surface of the cooling segment 107, 307.

In the examples of the article 301 shown in FIGS. 6 and 7, 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 volatilized components to provide additional cooling to the heated volatilized components.

Method of generating an aerosol

In another aspect of the disclosure is provided a method of generating an aerosol using a non-combustible aerosol provision system as described herein. In some embodiments, the method comprises heating the aerosol generating material to a temperature of less than or equal to 350°C. In some embodiments, the method comprises heating the aerosol generating material to a temperature of from about 220°C to about 280°C. In some embodiments, the method comprises heating at least a portion of the aerosol generating material to a temperature from about 220°C to about 280°C during a session of use. "Session of use” as used herein refers to a single period of use of the non-combustible aerosol provision system by a user. The session of use begins at the point at which power is first supplied to at least one heating unit present in the heating assembly. The device will be ready for use after a period of time has elapsed from the start of the session of use. The session of use ends at the point at which no power is supplied to any of the heating elements in the aerosol generating device. The end of the session of use may coincide with the point at which the smoking article is depleted (the point at which the total particulate matter yield (mg) in each puff would be deemed unacceptably low by a user). The session will have a duration of a plurality of puffs. Said session may have a duration less than 7 minutes, or 6 minutes, or 5 minutes, or 4 minutes and 30 seconds, or 4 minutes, or 3 minutes and 30 seconds. In some embodiments, the session of use may have a duration of from 2 to 5 minutes, or from 3 to 4.5 minutes, or 3.5 to 4.5 minutes, or suitably 4 minutes. A session may be initiated by the user actuating a button or switch on the device, causing at least one heating element to begin rising in temperature.

EXAMPLE

Aspects of the present invention are more fully illustrated by the following example, which are set forth to illustrate certain aspects of the present invention and are not to be construed as limiting thereof. Unless otherwise noted, all parts and percentages are by dry weight.

Example 1. Tobacco-Coated Foamed Cast Sheet

An example of a foamed cast sheet embodiment (aerosol generating material) of the disclosure is prepared according to the formula provided in Table 1. The actual ingredients and percentages can be varied depending on the desired properties of the final product.

A slurry comprising the components listed in Table 1 in water is prepared and aerated as described herein above. The foamed slurry is then cast onto a 22-inch-wide stainless steel conveyer belt using a casting knife set at 2-5 mm gap opening. Tobacco material (shorts, 1-2 mmx3 mm) are deposited onto the wet foam sheet and adhere to the wet slurry. The coated, cast material is subsequently dried into a sheet by conveying the film through a 200 feet convection tunnel dryer, comprising multiple heated zones (e.g., ranging from 80-150°C). The sheet is dried to about 8 to 10% moisture.

The aerosol generating material thus prepared provides a substrate having reduced density but retaining good sensory performance properties. Particularly, the use of a foam forming agent (e.g., HPMC) allows air to be incorporated into the thin film and the density to be decreased.

Table 1. Foamed Cast Sheet Formula

Claims

1. An aerosol generating material in the form of a sheet, which may or may not be foamed, the sheet having a surface, the aerosol generating material comprising:

(ii) a filler;

(iii) an aerosol former material; and

2. The aerosol generating material of claim 1, wherein the sheet is foamed, the foamed sheet comprising one or more foam forming agents.

3. The aerosol generating material of claim 2, further comprising from about 1 to about 6 wt% of a foam stabilizing agent.

4. The aerosol generating material of claim 3, wherein the foam stabilizing agent comprises one or more surfactants or emulsifiers.

5. The aerosol generating material of claim 3, wherein the foam stabilizing agent comprises sodium lauryl sulfate, sorbitan monostearate, sorbitan monooleate, polyoxyethylene sorbitan monostearate, polyethylene glycol sorbitan monooleate, cocamidopropyl betaine, lecithin, or a combination thereof.

6. The aerosol generating material of claim 2, further comprising an effervescent agent.

7. The aerosol generating material of claim 6, wherein the effervescent agent comprises: calcium carbonate, sodium carbonate, sodium bicarbonate, or a combination thereof; and citric acid, tartaric acid, acetic acid, aluminum sulfate, or a combination thereof.

8. The aerosol generating material of claim 2, wherein the aerosol generating material comprises from about 5 to about 35 wt% of foam forming agent.

9. The aerosol generating material of claim 2, wherein the foam forming agent comprises hydroxypropyl methylcellulose (HPMC), a gum, a modified starch, maltodextrin, or a combination thereof.

10. The aerosol generating material of claim 2, wherein the foam forming agent comprises hydroxypropyl methylcellulose (HPMC).

11. The aerosol generating material of claim 1, wherein the sheet is not foamed, and wherein the aerosol generating material comprises one or more binding agents.

12. The aerosol generating material of claim 11, wherein the one or more binding agents comprise carboxymethyl cellulose, alginate, a natural gum, or a combination thereof.

13. The aerosol generating material of claim 1 , wherein the aerosol generating material comprises from about 10 to about 85 wt% of the filler.

14. The aerosol generating material of claim 1, wherein the filler comprises wood pulp, microcrystalline cellulose, or a combination thereof.

15. The aerosol generating material of claim 1, comprising from about 20 to about 30% by weight of the aerosol former material.

16. The aerosol generating material of claim 1, wherein the aerosol former material comprises glycerol, propylene glycol, 1,3 -propanediol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, propylene carbonate, or a combination thereof.

17. The aerosol generating material of claim 1, wherein the aerosol former material is glycerol, propylene glycol, or a combination thereof.

18. The aerosol generating material of claim 1, wherein the sheet has a density in a range from about 0.02 g/cm³ to about 0.7 g/cm³.

19. The aerosol generating material of claim 1, wherein the aerosol generating material has a fill value of more than about 380 g/cm³ as determined by the formula: fill value = (bulk volume / weight) x 100; wherein the bulk volume is determined using a densimeter.

20. The aerosol generating material of claim 1, wherein the aerosol generating material has a porosity of about 100 s/100 mL or more as determined using a Gurley Densometer.

21. The aerosol generating material of claim 1, wherein the tobacco material is a particulate or fibrous tobacco.

22. The aerosol generating material of claim 21, wherein the fibrous tobacco material has a width in a range from about 1 to about 2 mm, and a length of up to about 3 mm.

23. The aerosol generating material of claim 21, wherein the particulate tobacco material is powdered tobacco.

24. The aerosol generating material of any one of claims 1-23, wherein the aerosol generating material is in a laminated form.

25. The aerosol generating material of any one of claims 1-23, further comprising a top coating of a filmforming agent disposed on the surface of the sheet and coating the tobacco material embedded in the sheet or adhered to the surface of the sheet.

26. The aerosol generating material of claim 25, wherein the film-forming agent is selected from the group consisting of hydroxypropyl cellulose, hydroxypropyl methylcellulose, carboxymethylcellulose, modified starches, maltodextrin, alginate, carrageenan, xanthan, gellan, gum acacia, gum tragacanth, monoglycerides, diglycerides, triethyl citrate, and combinations thereof.

27. An aerosol generating component comprising the aerosol generating material of any one of claims 1-26.

28. The aerosol generating component of claim 27, comprising from about 10 to about 100 wt% of the aerosol generating material.

29. The aerosol generating component of claim 27, wherein the aerosol generating material is in the form of a corrugated sheet.

30. The aerosol generating component of claim 27, wherein the aerosol generating material is in the form of a shredded sheet.

31. The aerosol generating component of claim 30, wherein the shredded sheet is blended with an additional tobacco material which is different in character from the tobacco material embedded in or adhered to the surface of the sheet.

32. The aerosol generating component of claim 31, wherein the additional tobacco material comprises reconstituted tobacco, tobacco lamina, fine-cut tobacco, cut-rag tobacco, or a combination thereof.

33. The aerosol generating component of claim 29, wherein the corrugated sheet is crimped and gathered into a cylindrical rod, the aerosol generating component further comprising a wrapping material circumscribing the rod.

34. A consumable for use in a non-combustible aerosol provision device, the consumable comprising the aerosol generating component of claim 27.

35. A non-combustible aerosol provision system comprising the consumable of claim 34 and a noncombustible aerosol provision device, the non-combustible aerosol provision device comprising an aerosol generating device arranged to generate aerosol from the consumable when the consumable is used with the non- combustible aerosol provision device.

36. A combustible aerosol provision system comprising the consumable of claim 34 and a combustible aerosol provision device.

37. A method of forming an aerosol generating material in the form of a sheet having a surface, and having a tobacco material embedded in the sheet or adhered to the surface thereof, the method comprising:

(a) providing a slurry comprising:

(ii) a filler;

(iii) an aerosol former material; and

(iv) a solvent;

(b) optionally, aerating the slurry to form an aerated slurry;

(c) forming a layer of the optionally aerated slurry;

38. The method of claim 37, wherein the sheet is foamed.

39. The method of claim 38, wherein aerating the slurry comprises mixing the slurry under high shear conditions.

40. The method of claim 37. wherein providing the slurry comprises mixing the slurry under high shear conditions, such that the aerating is performed as part of step (a).

41. The method of claim 38, wherein aerating the slurry comprises bubbling a gas through the slurry.

42. The method of claim 37, wherein aerating the slurry comprises adding an effervescent agent to the slurry, and allowing the effervescent agent to effervesce, thereby introducing gas bubbles into the slurry.

43. The method of claim 37, wherein the aerosol generating material is top-coated with a film-forming agent, the method further comprising: disposing the film-forming agent on the slurry following (d), and optionally drying the disposed filmforming agent to form the top-coated aerosol generating material.; or disposing the film-forming agent on the aerosol generating material following (e), and optionally drying the disposed film-forming agent to form the top-coated aerosol generating material.

44. The method of claim 43, wherein the film-forming agent is selected from the group consisting of hydroxypropyl cellulose, hydroxypropyl methylcellulose, carboxymethylcellulose, modified starches, maltodextrin, alginate, carrageenan, xanthan, gellan, gum acacia, gum tragacanth, monoglycerides, diglycerides, triethyl citrate, and combinations thereof.

45. The method of claim 37, wherein the aerosol generating material is in laminated form, the method further comprising: forming a second layer of the optionally aerated slurry on the layer of the optionally aerated slurry following (d) to form a layered composite; and drying the layered composite to form the aerosol generating material in laminated form.

46. The method of claim 37, wherein the aerosol generating material is in laminated form, the method further comprising: forming a second layer of the optionally aerated slurry on the aerosol generating material following (e) to form a layered composite; and drying the layered composite to form the aerosol generating material in laminated form.