TW202437926A - Aerosol-generating material - Google Patents

Abstract

The invention provides an aerosol-generating material comprising: aerosol-former material; a first binder which is a galactomannan gum; a second binder which is a hydroxypropyl methyl cellulose; and filler. The invention also provides aerosol-generating compositions comprising the aerosol-generating material, consumables for use in a non-combustible aerosol provision system, and non-combustible aerosol provision systems. The invention also provides methods for producing the aerosol-generating material.

Description

Aerosol Generating Materials

The present invention relates to aerosol generating technology. In particular, the present invention relates to aerosol generating materials, aerosol generating compositions, consumables, non-flammable aerosol supply systems, methods for generating aerosols, and methods for forming aerosol generating materials.

Smoking articles such as cigarettes, cigars and the like burn tobacco to create tobacco smoke during use. Alternatives to these types of articles release inhalable aerosols or vapors by releasing compounds from a base material upon heating without combustion. These may be referred to as non-combustible smoking articles, aerosol generating components or non-combustible aerosol delivery systems.

An example of such a product is a heating device that releases compounds by heating rather than burning a solid aerosolizable material. In some cases, the solid aerosolizable material may contain tobacco material. Heating at least one component of the volatile material typically forms an inhalable aerosol. Such products may be referred to as heat-not-burn devices, tobacco heating devices, or heated tobacco products (THPs). Various different configurations are known for volatile at least one component of a solid aerosolizable material.

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

In one embodiment, an aerosol generating material is provided, comprising: (i) an aerosol former material; (ii) a first binder, which is galactomannan gum; (iii) a second binder, which is hydroxypropyl methylcellulose; and (iv) a filler.

In another aspect, an aerosol generating composition is provided, comprising an aerosol generating material as described herein.

Also provided is a consumable for use in a non-flammable aerosol delivery device, the consumable comprising the aerosol generating composition described herein.

A non-flammable aerosol supply system is also provided, which includes the consumables described herein and a non-flammable aerosol supply device.

Also provided is a method of generating an aerosol using the non-flammable aerosol supply system described herein, the method comprising heating the aerosol generating material to a temperature less than 350°C.

In another embodiment, a method for making an aerosol generating material (such as the aerosol generating material described herein) is provided, the method comprising: (a) providing a slurry comprising an aerosol forming agent material, a first binder (which is galactomannan gum), a second binder (which is hydroxypropyl methylcellulose), a filler and a solvent; (b) aerating the slurry; (c) forming a layer of aerated slurry; and (d) drying the slurry to form the aerosol generating material.

Features described herein with respect to one aspect of the invention are expressly disclosed in combination with each and every other aspect, to the extent they can be combined.

Other features and advantages of the present invention will become apparent from the following description given by way of examples only and with reference to the accompanying drawings.

Aerosol-generating materials/compositions described herein are materials/compositions that are capable of generating an aerosol, for example, when heated, irradiated, or energized in any other manner.

The aerosol generating material may be an "amorphous solid". In some embodiments, the aerosol generating material comprises an aerosol generating film, which is an amorphous solid. In some embodiments, the amorphous solid is a "monolithic solid". The aerosol generating material may be non-fibrous or fibrous. For example, the aerosol generating material may be substantially non-fibrous. In some embodiments, the aerosol generating material may be a dry gel. The aerosol generating material is a solid material in which some fluid, such as a liquid, is retained. In some embodiments, the retained fluid may be water (such as water absorbed from the surrounding of the aerosol generating material) or the retained fluid may be a solvent (such as when the aerosol generating material is formed from a slurry). In some embodiments, the solvent may be water.

In some embodiments, the aerosol generating composition may, for example, comprise from about 50 wt%, 60 wt% or 70 wt% of aerosol generating material to about 90 wt%, 95 wt% or 100 wt% of aerosol generating material. In some cases, the aerosol generating composition consists of aerosol generating material. In other cases, the aerosol generating composition comprises from about 40 to about 60 wt% of aerosol generating material. The remainder of the composition may be formed by other components as described below, such as tobacco material.

In some embodiments, the aerosol generating material is a hydrogel and contains less than about 20 wt % water on a wet weight basis. In some cases, the hydrogel may contain less than about 15 wt %, 12 wt %, or 10 wt % water on a wet weight basis (WWB).

In some embodiments, the aerosol generating material may contain less than about 20 wt %, such as less than about 15 wt %, 12 wt %, or 10 wt % water on a wet weight basis (WWB). For example, the aerosol generating material may contain about 1-15 wt % water, such as 3-12 wt % water (WWB).

In some embodiments, the aerosol generating material has a filling value of at least about 2 cm ³ /g, 3 cm ³ /g, 4 cm ³ /g, 5 cm ³ /g. In some embodiments, the filling value is less than about 7.5 cm ³ /g, 7 cm ³ /g, or 6.5 cm ³ /g. In some embodiments, the aerosol generating material has a filling value of from about 2 cm ³ /g to about 7.5 cm ³ /g, from about 3 cm ³ /g to about 7 cm ³ /g, or from about 4 cm ³ /g to about 6.5 cm ³ /g.

Fill value is measured by placing a known weight of material in a cylinder of known dimensions. It is subjected to pressure from a weighted piston for 30 seconds. The remaining height of the compressed sample is measured and converted to volume. The fill value is then calculated as the volume of material divided by the mass.

In more detail, the filling value of the aerosol generating material of the present invention can be determined by the following process: 20 g of the material sample is deposited in a 60 mm diameter cylinder of a densitometer and then the material is compressed with a 2.90 ± 0.03 kg piston for 30 seconds. The height of the piston in the densitometer is measured. The filling value of the sample is calculated according to the following formula.

Use Equation 1 to determine the volume occupied by the material when compressed: r = radius of the cylinder (cm) h = measured height (cm)

The fill value is then determined using the measured volume and mass of the material according to Formula 2:

Filling values can also be provided in units of cm ³ /10g, where 1 cm ³ /g is equal to 10 cm ³ /10g.

Filling value (also referred to herein as fill value) is a measure of the volume occupied by a given mass of material when a given pressure is applied. That is, the filling value is a measure of the ability of a material to occupy a specific volume.

The inventors have found that the aerosol generating material of the present invention has a higher filling value than an aerosol generating material containing only one binder (such as galactomannan gum or hydroxypropylmethylcellulose).

By using a higher fill value material as the aerosol generating material, it is possible to provide articles and consumables that have an overall weight lower than conventional articles. Reducing the overall weight can provide many advantages, such as reducing shipping costs and reducing material costs and/or taxes. Furthermore, reducing the weight of the article may also have a positive impact on the environment because less energy is required to transport the article. In addition, consumers may prefer to carry and use articles that are lightweight. The material can also be used as a non-tobacco containing aerosol generating substrates.

In some embodiments, the aerosol generating material has a tensile strength of from about 1 N/15 mm, 2 N/15 mm, 4 N/15 mm, or 5 N/15 mm to about 18 N/15 mm, 16 N/15 mm, 14 N/15 mm, or 12 N/15 mm. In some embodiments, the tensile strength of the aerosol generating material is in the range of from about 1 N/15 mm to about 18 N/15 mm, from about 2 N/15 mm to about 16 N/15 mm, from about 4 N/15 mm to about 16 N/15 mm, or from about 5 N/15 mm to about 12 N/15 mm.

Tensile strength was measured using a Stable Microsystems Texture Analyser. Sheet samples were cut to 15 mm width x 140 mm length.   The 25 mm ends of the sample were folded over to give a total length of 90 mm with a single thickness section of 40 mm in the center.

The prepared material sample is held between two clamping plates which are separated by a measured force and 5 mm distance movement via the Texture Analyser armature. The Texture Analyser device lifts one of the plates and measures and records the force required to do so over the distance it travels. The software associated with the device sets the test parameters and records the force required, and the data can then be exported as required.

Use formula 3 to measure the tensile strength of the material:

Tensile strength is the resistance of an object or material to longitudinal stress, the force required to pull it to fracture, or the force required to pull it past elastic deformation to the point of plastic deformation. It is related to the toughness of an object or material, in that the higher the tensile strength, the more difficult it is to stretch or break in tension.

In some embodiments, the aerosol generating material has a viscosity of at least about 0.01 N, 0.05 N, 0.1 N, or 0.15 N. In some embodiments, the viscosity is less than about 0.3 N, 0.25 N, or 0.2 N. In some embodiments, the aerosol generating material has a viscosity from about 0.01 N to about 0.3 N, from about 0.01 N to about 0.35 N, or from about 0.01 N to about 0.2 N.

Adhesion is measured using the Texture Analyser device. Samples measuring 7 cm x 7 cm are cut from the sheet. The sheet sample is fixed to an aluminum plate. The Texture Analyser device then lowers the probe onto the sheet at a force of 4.5 N for 5 seconds, then lifts it up and measures the force required to do so. The software associated with the device sets the test parameters and records the force required, and the data can then be exported as required.

Adhesion is a material property of adhesion/tack. It is the force required to overcome the attraction between the product surface and a reference material, which in this case is a metal probe attached to the Texture Analyser device in contact with the product .

The aerosol generating material comprises a first binder, which is galactomannan glue, and a second binder, which is hydroxypropylmethylcellulose. The term "gelling agent" may also be used in this article to replace "binder".

Advantageously, the aerosol generating material has sufficient tensile strength to allow the aerosol generating material to be wound (e.g., in sheet form) onto a spool and unrolled without breaking. It is also desirable that the aerosol generating material has a high filling value. It has been found that aerosol generating materials having sufficient tensile strength (e.g., 5 N/15 mm) can be produced using hydroxypropyl methylcellulose as a binder. However, the filling value of such aerosol generating materials may be relatively low. Surprisingly, it has been found that replacing a portion of the hydroxypropylmethylcellulose binder with galactomannan gum as the second binder can increase the filling value of the resulting aerosol generating material while still allowing the production of an aerosol generating material with sufficient tensile strength (e.g., at least 5 N/15 mm).

Suitable galactomannan gums include, but are not limited to, fenugreek gum, guar gum, tara gum, locust bean gum, and cassia gum. In a specific embodiment, the galactomannan gum is locust bean gum.

In some embodiments, the aerosol-generating material comprises from about 1 wt%, 1.5 wt%, or 2 wt% to about 10 wt%, 7 wt%, or 5 wt% of the first binder (galactomannan gum). For example, in some embodiments, the aerosol-generating material comprises from about 1 to about 10 wt%, from about 1.5 to about 7 wt%, or from about 2 to about 5 wt% of the first binder.

In some embodiments, the aerosol-generating material comprises from about 1 wt%, 1.5 wt%, or 2 wt% to about 10 wt%, 9 wt%, 8 wt%, or 7 wt% of a second binder (hydroxypropylmethylcellulose). For example, in some embodiments, the aerosol-generating material comprises from about 1 to about 10 wt%, from about 1.5 to about 8 wt%, or from about 2 to about 7 wt% of a second binder.

In some embodiments, the aerosol generating material comprises a first and a second binder in an amount of from about 2 wt%, 3 wt%, 4 wt%, or 5 wt% to about 15 wt%, 14 wt%, 13 wt%, or 11 wt% of the aerosol generating material on a dry weight basis. For example, in some embodiments, the total amount of the first and the second binder in the aerosol generating material is from about 2 to about 15 wt%, from about 3 to about 14 wt%, from about 4 to about 13 wt%, or from about 5 to about 11 wt%. Additional Binder

In addition to the first and second binders, the aerosol generating material may further include one or more additional binders other than galactomannan gum or hydroxypropylmethylcellulose.

In some embodiments, the additional adhesive comprises a hydrocolloid and/or a swelling agent.

In some embodiments, the additional adhesive includes (or is) a swelling agent.

In some embodiments, the additional binder comprises one or more compounds selected from the group consisting of polysaccharide binders such as alginates, pectin, cellulose or derivatives thereof, polytriglucose, carageenan, agar and agarose; tartaric acid; non-galactomannan gums such as xanthan gum and gum arabic; silica or polysilicone such as PDMS and sodium silicate; clays such as kaolin; and polyvinyl alcohol.

In some embodiments, the additional binder comprises one or more polysaccharide binders. In some embodiments, the polysaccharide binder is selected from alginate, pectin, and cellulose or a derivative thereof.

Examples of cellulose binders (also known as cellulose derivatives) include, but are not limited to, hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose (CMC), hydroxypropyl methyl cellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), and cellulose acetate propionate (CAP). In some embodiments, cellulose or its derivative is selected from hydroxymethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose (CMC), hydroxypropylmethylcellulose (HPMC), methylcellulose, ethylcellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB) and cellulose acetate propionate (CAP). In a specific embodiment, the cellulose derivative is CMC.

In some embodiments, the additional binder comprises tartaric acid, which can increase the filling value of the aerosol-generating material.   For example, using tartaric acid in combination with galactomannan gum and hydroxypropyl methylcellulose can increase the filling value of the aerosol-generating material.   Including tartaric acid as an additional binder can also help reduce the tackiness of the surface of the aerosol-generating material, such as when it contains a high concentration of aerosol-forming material, thereby facilitating the processing and/or handling of the aerosol-generating material (during its manufacture and/or subsequent processing).

The use of tartaric acid can also improve the tensile strength of aerosol-generating materials.

In some embodiments, the aerosol generating material comprises from about 1 wt%, 2 wt%, or 3 wt% to about 10 wt%, 9 wt%, 8 wt%, or 7 wt% tartaric acid. For example, the aerosol generating material may comprise tartaric acid in an amount from about 1 to about 10 wt%, such as from about 2 to about 8 wt% or from about 3 to about 7 wt%.

In some embodiments, the only binders are the first and second binders (i.e., galactomannan gum and hydroxypropylmethylcellulose). Aerosol Forming Agent Materials

The aerosol forming agent material may include one or more components capable of forming an aerosol. In some embodiments, the aerosol forming agent material includes one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, tetratetrol, meso-tetratetrol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, glyceryl triacetate, diacetate glyceryl mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

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

In certain embodiments, the aerosol former material comprises a combination of glycerol and propylene glycol. In certain embodiments, the aerosol former material comprises glycerol.

The aerosol generating material may comprise from about 1 wt % to about 60 wt % of an aerosol former material. In some embodiments, the aerosol generating material may comprise from about 1 wt %, 10 wt %, 20 wt %, 30 wt % or 40 wt % to about 60 wt %, 55 wt %, 50 wt %, 45 wt % or 40 wt % of an aerosol former material.   In specific embodiments, the aerosol generating material comprises from about 10 to about 60 wt % or from about 20 to about 55 wt % of an aerosol former material.

In some embodiments, the aerosol generating material comprises from about 20 to about 40 wt % or from about 25 to about 35 wt % aerosol former material, such as about 30 wt %.

In some embodiments, the aerosol generating material comprises from about 40 to about 60 wt % or from about 45 to about 55 wt % of the aerosol former material, such as about 50 wt %. Filler

The aerosol generating material includes a filler. The use of a filler can help reduce the viscosity of the aerosol generating material, for example if a high level of aerosol former material is present.

In some embodiments, the aerosol generating material comprises about 1 to 80 wt % of the filler on a dry weight basis. For example, in some embodiments, the aerosol generating material comprises from about 30 to about 70 wt % of the filler or from about 40 to about 60 wt % of the filler.

In some embodiments, the filler comprises (or is) one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents, such as molecular sieves.

In some embodiments, the filler comprises (or is) one or more organic filler materials, such as wood pulp; tobacco pulp; hemp fiber; cellulose and cellulose derivatives, such as microcrystalline cellulose and/or nanocrystalline cellulose.

As will be well understood by those skilled in the art, microcrystalline cellulose can be formed by depolymerizing cellulose by chemical methods (e.g., using an acid or an enzyme). An exemplary method for forming microcrystalline cellulose involves acid hydrolysis of cellulose using an acid (such as HCl). The cellulose produced after this treatment is crystalline (i.e., no amorphous regions remain). Methods and conditions suitable for forming microcrystalline cellulose are well known in the art.

In some embodiments, the aerosol generating material does not contain an inorganic filler. In some embodiments, the aerosol generating composition does not contain an inorganic filler.

In some embodiments, the aerosol generating material does not contain calcium carbonate, such as chalk.

In some embodiments, the aerosol generating composition does not contain calcium carbonate, such as chalk.

In a specific embodiment, the aerosol generating material includes a filler and the filler is fibrous. For example, the filler can be a fibrous organic filler material, such as wood pulp, tobacco pulp, hemp fiber, cellulose or a cellulose derivative. In some embodiments, the fibrous organic filler material can be wood pulp, hemp fiber, cellulose or a cellulose derivative. In a specific embodiment, the fibrous filler is wood pulp. Without wishing to be bound by theory, it is believed that including a fibrous filler in the aerosol generating material can increase the tensile strength of the material. This may be particularly advantageous in instances where the aerosol generating material is provided in a sheet, such as when the sheet of aerosol generating material surrounds a rod of aerosolizable material.

In certain embodiments, the filler comprises microcrystalline cellulose and/or wood pulp. Optional Active Ingredients

The aerosol-generating material or aerosol-generating composition may comprise an active substance.

In some cases, the aerosol-generating material may comprise from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 65 wt%, 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (on a dry weight basis) of the active substance.

In some cases, the active substance is nicotine. In some cases, the aerosol generating material can include from about 1 wt%, 2 wt%, 3 wt%, 4 wt%, or 5 wt% to about 20 wt%, 18 wt%, 15 wt%, 12 wt%, or 10 wt% (calculated on a dry weight basis) of nicotine. For example, the aerosol generating material can include about 1-20 wt%, 2-18 wt%, or 3-12 wt% nicotine.

As used herein, active substances may be physiologically active materials, which are materials intended to achieve or enhance a physiological response. Active substances may be selected, for example, from nutraceuticals, smart drugs, psychoactive agents. Active substances may occur naturally or be obtained synthetically. Active substances may include, for example, niacin, caffeine, taurine, theophylline, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or components, derivatives or combinations thereof. Active substances may include one or more components, derivatives or extracts of tobacco, cannabis or another plant.

In some embodiments, the active substance comprises niacin. In one embodiment, the active substance comprises caffeine, melatonin or vitamin B12.

As described herein, an active substance may comprise one or more components, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.

In some embodiments, the active substance comprises one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiolic acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabichromene (CBC), cannabichromene (CBL), cannabinol (CBV), tetrahydrocannabinol (THCV), cannabidiol (CBDV), cannachromene (CBCV), cannabigerol (CBGV), cannabigerol monomethyl ether (CBGM) and cannabielsoin (CBE), cannabidiol (CBT).

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

The active ingredient may include cannabidiol (CBD).

Active ingredients may include niacin and cannabidiol (CBD).

Active ingredients may include niacin, cannabidiol (CBD) and tetrahydrocannabinol (THC).

As described herein, an active substance may comprise or be derived from one or more plants or components, derivatives or extracts thereof. As used herein, the term "botanical" includes any material derived from a plant, including but not limited to extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, rinds, shells, or the like. Alternatively, the material may comprise an active compound that occurs naturally in a botanical that is obtained synthetically. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, chips, strips, sheets, or the like. Examples of botanicals are tobacco, eucalyptus, star anise, cannabis, cocoa, marijuana, fennel, lemongrass, mint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, bay, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, green or black tea, thyme, cloves, cinnamon, coffee, aniseed (aniseed), basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, holly, basil, ginger yellow, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, black currant, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chives, kudzu, verbena, tarragon, geranium, mulberry, ginseng, theanine, theanine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. The mint may be selected from the following mint species: wild mint (Mentha arventis), peppermint (Mentha c.v.), Egyptian mint (Mentha niliaca), peppermint (Mentha piperita), lemon peppermint (Mentha piperita citrata c.v.), chocolate mint (Mentha piperita c.v.), wrinkled mint (Mentha spicata crispa), heart mint (Mentha cardifolia), European peppermint (Mentha longifolia), pineapple mint (Mentha suaveolens variegate), lip calyx mint (Mentha pulegium), spearmint (Mentha spicata c.v.), and apple mint (Mentha suaveolens).

In some embodiments, the active substance comprises or is derived from one or more plants or components, derivatives, or extracts thereof, and the plant is Nicotiana tabacum.

In some embodiments, the active substance comprises or is derived from one or more plants or components, derivatives or extracts thereof, and the plant is selected from eucalyptus, star anise, cocoa and cannabis.

In some embodiments, the active ingredient comprises or is derived from one or more plants or components, derivatives or extracts thereof, and the plant is selected from Rooibos tea and fennel.

In some embodiments, the aerosol generating material does not contain tobacco fibers. In some embodiments, the aerosol generating material does not contain tobacco materials. In some embodiments, the aerosol generating material is substantially free of tobacco materials. In some embodiments, the aerosol generating material does not contain active substances. Flavoring agents

In some embodiments, the aerosol-generating material or aerosol-generating composition comprises a flavoring agent.

In some cases, the aerosol generating material may comprise from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 65 wt%, 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (on a dry weight basis) of the flavorant.

As used herein, the terms "flavour" and "flavourant" refer to materials that can be used to create a desired taste, aroma or other sensory sensation in a product for adult consumers, where permitted by local regulations. They can include naturally occurring flavouring materials, botanicals, botanical extracts, synthetically derived materials or combinations thereof (e.g., tobacco, marijuana, licorice, liquorice), hydrangea, eugenol, Japanese magnolia leaf, chamomile, fenugreek, cloves, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian flavors, Asian flavors, herbs, wintergreen, cherry, berry, cranberry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, pitaya, cucumber, blueberry, mulberry, citrus fruit, Dram buie), bourbon, scotch whiskey, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe, cardamom, celery, sage, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel nut, tobacco, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cinnamon, kudzu, cognac, jasmine, ylang-ylang, sage, fennel, horseradish, allspice, ginger, Coriander, coffee, cannabis, mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, Rooibos tea, flax, ginkgo, hazel, hibiscus, laurel, mate, orange peel, rose, tea (green or black), thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, basil, turmeric, cilantro, myrtle, black currant, valerian, pimento, mace, damiensis, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, basil, turmeric, cilantro, myrtle, black currant, valerian, pimento, mace, damiensis, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, basil, turmeric, cilantro, myrtle, black currant, valerian, pimento, mace, damiensis, turmeric, cilantro, turmeric ien), marjoram, olive, lemon balm, lemon basil, chives, kudzu, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, sodium cyclamate, lactose, sucrose, glucose, fructose, sorbitol or mannitol) and other additives such as charcoal, chlorophyll, minerals, botanicals or breath fresheners. They can be simulated, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example liquid (such as oil), solid (such as powder) or gas.

In some embodiments, the flavor comprises menthol, green mint and/or peppermint. In some embodiments, the flavor comprises a flavor component of cucumber, blueberry, citrus fruit and/or cranberry. In some embodiments, the flavor comprises eugenol. In some embodiments, the flavor comprises a flavor component extracted from tobacco. In some embodiments, the flavor comprises a flavor component extracted from cannabis.

In some embodiments, the flavoring agent may include a sensory agent, which is intended to achieve a physical sensation, which is usually chemically induced and perceived by stimulating the fifth cranial nerve (trigeminal nerve) in addition to or instead of the aroma or taste nerves, and such sensory agents may include agents that provide heating, cooling, tingling, numbing effects. Suitable thermal effect agents may be, but are not limited to, vanillin ether and suitable cooling agents may be, but are not limited to, eucalyptol, WS-3. Other functional materials

In some embodiments, the aerosol generating material or aerosol generating composition may further include one or more other functional materials. The one or more other functional materials may include one or more of a pH adjuster, a colorant, a preservative, a stabilizer and/or an antioxidant.

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

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

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

In embodiments where the aerosol generating material comprises nicotine, it is particularly preferred to include an acid. In such embodiments, the presence of the acid can stabilize dissolved species in the slurry that forms the aerosol generating material. The presence of the acid can reduce or substantially prevent evaporation of nicotine during slurry drying, thereby reducing nicotine losses during manufacturing.

The aerosol generating material may include a colorant. The addition of a colorant may change the visual appearance of the aerosol generating material. The presence of a colorant in the aerosol generating material may enhance the visual appearance of the aerosol generating material and the aerosol generating composition. By adding a colorant to the aerosol generating material, the aerosol generating material may be matched in color to other components of the aerosol generating composition or other components of a consumable that includes 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, or black. Other colors are also contemplated. Natural or synthetic colorants may be used, such as natural or synthetic dyes, food grade colorants, and pharmaceutical colorants. In certain embodiments, the colorant is caramel, which may give the aerosol generating material 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 the aerosol generating composition that includes the aerosol generating material. In some embodiments, a colorant is added to the aerosol generating material so that it is visually indistinguishable from other components of the aerosol generating composition.

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

In some embodiments, the aerosol generating material is formed as a sheet. In some cases, the sheet of aerosol generating material can be incorporated into a non-flammable aerosol supply system or consumable in sheet form. The sheet of aerosol generating material can be incorporated in the form of a flat sheet, a gathered or bundled sheet, a rolled sheet, or a rolled sheet (i.e., a tubular form). In some such cases, the aerosol generating material of these embodiments can be contained in the system/consumable as a sheet, such as a sheet surrounding a rod of an aerosolizable material (e.g., tobacco). For example, the sheet of aerosol generating material can be formed on a roll of paper surrounding an aerosolizable material such as tobacco. In other cases, the sheet material may be shredded and subsequently incorporated into the assembly, suitably mixed into an aerosolizable material such as tobacco.

In some cases, the aerosol generating material may be in the form of a sheet or layer having a thickness of about 0.015 mm to about 1.0 mm. Suitably, the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm, for example 0.1-3 mm or 0.15-3 mm. A material having a thickness of 0.2 mm may be particularly suitable. The aerosol generating material may comprise more than one layer, and the thickness described herein refers to the total thickness of those layers.

If the aerosol generating material is too thick, the heating efficiency may be compromised. This can have an adverse effect on the power consumption in use. Conversely, if the aerosol generating material is too thin, it may be difficult to manufacture and handle; extremely thin materials are more difficult to cast and may be brittle, which can affect aerosol formation in use.

The thickness specified herein is the average thickness of the material. In some cases, the aerosol generating material thickness may vary by no more than 25%, 20%, 15%, 10%, 5% or 1%.

In some embodiments, the aerosol-generating material in sheet form may have sufficient tensile strength to allow it to be wound onto a winding spool or unwound from a spool without breaking. In some examples, the aerosol-generating material in sheet form has a tensile strength greater than or equal to about 250 N/m.

The aerosol generating material may have any suitable area density, such as from 30 g/ ^m2 to 120 g/ ^m2 . In some cases, the aerosol generating material may have a mass per unit area (so that it will not readily separate when mixed with tobacco, such as tobacco) of from about 80 to 120 g/ ^m2 , or from about 70 to 110 g/ ^m2 , or particularly from about 90 to 110 g/ ^m2 , or suitably about 100 g/ ^m2 . Such area densities may be particularly suitable when the aerosol generating material is included in the consumable/system in sheet form or shredded material (described further below). Aerosol generating composition

One aspect provides an aerosol generating composition comprising an aerosol generating material as defined herein.

In some embodiments, the aerosol generating composition further comprises tobacco material. In such embodiments, the tobacco material does not form a part of the aerosol generating material. That is, it is present in the aerosol generating composition separately from the aerosol generating material.

As used herein, the term "tobacco material" refers to any material comprising tobacco or a derivative thereof. The term "tobacco material" may include one or more of tobacco, a tobacco derivative, expanded tobacco, reconstituted tobacco, or a tobacco substitute. The tobacco material may include one or more of the following: ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, reconstituted tobacco, and/or a tobacco extract.

The tobacco used to make the tobacco material may be any suitable tobacco, such as a single type or a blend, tobacco shreds or whole leaves, 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 ground tobacco or reconstituted tobacco material. Reconstituted tobacco material may include tobacco fibers and may be formed by casting, Fourdrinier-based papermaking processes by back addition of tobacco extracts, or by extrusion.

In some embodiments, the amount of aerosol forming material in the aerosol generating composition is from about 5 to about 30 wt % of the aerosol generating composition on a dry weight basis. For example, in some embodiments, the aerosol generating composition comprises an amount of aerosol forming material from about 10 to about 20 wt % or from about 13 to about 17 wt %. In some embodiments, the aerosol generating composition comprises an amount of aerosol forming material of about 15 wt %. This amount includes any aerosol forming material present in the aerosol generating composition, such as aerosol forming material provided in the aerosol generating material and any aerosol forming material loaded onto the tobacco material.

It has been found that tobacco-tobacco blends that are typically used alone in conventional combustible smoking products such as cigarettes are not suitable for use in non-flammable aerosol delivery devices. Without wishing to be bound by theory, it is believed that tobacco-tobacco blends used in cigarettes are typically unable to be loaded with sufficient aerosol former material to provide the desired inhalable aerosol when heated by a non-flammable aerosol delivery device.

Previous attempts to address this problem have included replacing some or all of the tobacco in a typical combustible tobacco blend with reconstituted tobacco, such as paper reconstituted tobacco. Paper reconstituted tobacco can generally contain a greater proportion of aerosol former materials. However, tobacco blends containing a high proportion of paper reconstituted tobacco may have undesirable organoleptic properties when heated by a non-flammable aerosol supply device.

By providing a combination of an aerosol generating material and a tobacco material having a high aerosol former material content, it is possible to produce an acceptable aerosol without requiring the presence of significant amounts of reconstituted tobacco (thereby reducing undesirable organoleptic properties associated with reconstituted tobacco).

In some embodiments, the tobacco material comprises or consists of flaked tobacco (such as tadalafil) that provides desired organoleptic properties.

In some embodiments, the tobacco material comprises reconstituted tobacco in an amount of less than about 50 wt%, 30 wt%, 10 wt%, 5 wt%, or 1 wt% based on the dry weight of the tobacco material. In some embodiments, the tobacco material comprises substantially no reconstituted tobacco.

The tobacco material may be present in any format, but is typically finely chopped (e.g., cut into narrow pieces). Finely chopped tobacco material may advantageously be blended with an aerosol generating material to provide an aerosol generating composition having a uniform dispersion of the tobacco material and the aerosol generating material throughout the aerosol generating composition.

In some embodiments, the tobacco material comprises one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stalks, reconstituted tobacco, and/or a tobacco extract. It is possible to use relatively large amounts of flaked tobacco in the aerosol generating composition and still provide an acceptable aerosol when heated by a non-flammable aerosol supply system. Flaked tobacco generally provides excellent sensory properties. In an example, the tobacco material comprises flaked 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 certain embodiments, 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 make the tobacco material may be any suitable tobacco, such as a single type or a blend, tobacco shreds or whole leaves, including Virginia tobacco and/or Burley tobacco and/or Oriental tobacco.

The tobacco material may generally be present in the aerosol generating composition in an amount from about 50 to 95 wt %, or about 60 to 95 wt %, or about 70 to 90 wt %, or about 80 to 90 wt % of the aerosol generating composition.

In some embodiments, the aerosol generating material is present in the aerosol generating composition in an amount of about 5-40 wt%, 5-30 wt%, 5-25 wt%, or 10-25 wt%, or 10-20 wt%. Surprisingly, by configuring the aerosol generating material to have a relatively high aerosol former material content, a relatively small amount of aerosol generating material (e.g., about 10-20 wt%) can be employed in the aerosol generating composition while still achieving a desired aerosol when used with a non-flammable aerosol supply system.

In some embodiments, the aerosol-generating composition consists of, or consists essentially of, an aerosol-generating material and a tobacco material.

In some embodiments, the tobacco material itself comprises an aerosol former material. Typically, the tobacco material comprises finely chopped tobacco, and the aerosol former material is loaded onto the tobacco fragments. In an example, the tobacco material comprises an aerosol former material in an amount from about 1 to 10 wt %, such as about 3 to 6 wt %, of the tobacco material. The aerosol former material defined above with respect to the aerosol generating material is also suitable for use in the tobacco material.

The aerosol generating material may be present in the aerosol generating composition in any suitable form. In an example, the aerosol generating material is present in sheet form. In an example, the aerosol generating material is present as a shredded material (e.g., the aerosol generating composition comprises fragments of the aerosol generating material). In an example, the aerosol generating material is present as a shredded material and is blended with finely chopped and/or shredded tobacco material, for example, the aerosol generating material and the tobacco material are in a similar form. Advantageously, providing the aerosol generating material and the tobacco material in fragmented/finely chopped portions allows the aerosol generating material and the tobacco material to have a uniformly dispersed aerosol generating composition blend throughout the aerosol generating composition.

In an example, the aerosol generating material has an area density from about 90 to 110% of the area density of any tobacco material in the aerosol generating composition. That is, the aerosol generating material and the tobacco material have similar area densities. Configuring the aerosol generating material and the tobacco material to have similar area densities allows for better blending of the aerosol generating material and the tobacco material when they are typically provided as shredded materials. For example, aerosol generating materials in the form of shredded materials and tobacco tobacco having similar area densities can be blended to provide a more homogeneous aerosol generating composition (e.g., better distribution of each component throughout the aerosol generating composition).

Fine cut tobacco (such as shredded tobacco) has a cutting width, which is usually expressed as CPI (cuts per inch) and refers to the width of a piece of tobacco. In some examples, where the tobacco material is fine cut (e.g., the tobacco material includes shredded tobacco) and the aerosol generating material is a shredded material, the cutting width of the aerosol generating material is from about 90 to 110% of the cutting width of the shredded tobacco. That is, the aerosol generating material and the tobacco material have similar cutting widths or shredding widths. Configuring the aerosol generating material and the tobacco material to have similar cutting widths allows for better blending of the aerosol generating material and the tobacco material. For example, shredded aerosol generating material sheets and tobacco having similar cut widths can be blended to provide a more homogeneous aerosol generating composition (e.g., better distribution of each component throughout the aerosol generating composition). The tobacco material can have a length of 1-4 cm.

The aerosol generating composition may include a carrier on which the aerosol generating material is provided. The carrier acts as a support on which the aerosol generating material is formed for ease of manufacture. The carrier may provide tensile strength to the aerosol generating material layer for ease of handling.

In some cases, the carrier may be formed of a material selected from metal foil, paper, carbon paper, greaseproof paper, ceramic, carbon allotropes such as graphite and graphene, plastic, cardboard, wood, or a combination thereof. In some cases, the carrier may contain or consist of a tobacco material, such as a reconstituted tobacco sheet. In some cases, the carrier may be formed of a material selected from metal foil, paper, cardboard, wood, or a combination thereof. In some cases, the carrier itself is a laminated structure comprising multiple layers of a material selected from the foregoing list. In some cases, the carrier may also function as a flavoring agent carrier. For example, the carrier may be impregnated with a flavoring agent or a tobacco extract.

In some cases, the carrier may be magnetic. This feature may be used to secure the carrier to a non-flammable aerosol supply device during use, or may be used to produce a specific aerosol generating material shape. In some cases, the aerosol generating material may include one or more magnets, which may be used to secure the material to an induction heater during use.

In some cases, the carrier may be substantially or completely impermeable to gases and/or aerosols. This may prevent aerosols or gases from passing through the carrier layer, thereby controlling the flow and ensuring its delivery to the user. This may also be used to prevent condensation or other deposition of the gas/aerosol in use on the surface of a heater, such as provided in an aerosol generation assembly. Thus, consumption efficiency and hygiene may be improved in some cases.

In some cases, the surface of the carrier adjacent to the aerosol generating material may be porous. For example, in one case, the carrier comprises paper. Porous carriers such as paper have been found to be particularly suitable; the porous (e.g., paper) layer is adjacent to the aerosol generating material and forms a strong bond. The aerosol generating material can be formed by drying a slurry, and without being limited by theory, it is believed that the slurry partially impregnates the porous carrier (e.g., paper), causing the carrier to be partially bonded into the aerosol generating material. This provides a strong bond between the aerosol generating material and the carrier.

In some embodiments, the aerosol generating material may be laminated to a carrier such as a paper sheet.

In some embodiments, when an aerosol generating material is formed from a slurry as described herein, a layer of the slurry may be formed on a carrier (e.g., a paper sheet).

Furthermore, the surface roughness may contribute to the strength of the bond between the aerosol generating material and the carrier. The paper roughness (with respect to the surface adjacent to the carrier) may suitably be in the range of 50-1000 Bekk seconds, suitably 50-150 Bekk seconds, suitably 100 Bekk seconds (measured in the air pressure interval of 50.66-48.00 kPa). (A Bekk smoothness tester is an instrument for determining the smoothness of a paper surface, wherein air of a specified pressure is leaked between a smooth glass surface and a paper sample, and the time (in seconds) between a fixed volume of air penetrating these surfaces is the "Bekk smoothness".)

Conversely, the surface of the carrier remote from the aerosol generating material may be configured to contact the heater, and a smoother surface may provide more efficient heat transfer. Thus, in some cases, the carrier is configured to have a rougher side adjacent to the aerosol generating material and a smoother side remote from the aerosol generating material.

In one particular case, the carrier may be a paper backing foil; the paper layer is adjacent to the aerosol generating material, and the properties discussed in the previous paragraph are imparted by this proximity. The foil backing is substantially impermeable, thereby providing control over the aerosol flow path. Metal foil backings may also be used to conduct heat to the aerosol generating material.

In another embodiment, a foil layer of a paper backing foil is adjacent to the aerosol generating material. The foil is substantially impermeable, thereby preventing water provided in the aerosol generating material from being absorbed into the paper, which could weaken its structural integrity.

In some cases, the carrier is formed of or includes a metal foil, such as an aluminum foil. The metal carrier can allow for better conduction of thermal energy to the aerosol generating material. Additionally or alternatively, the metal foil can act as a susceptor in an induction heating system. In certain embodiments, the carrier comprises a metal foil layer and a support layer, such as cardboard. In such embodiments, the metal foil layer can have a thickness of less than 20 μm, such as from about 1 μm to about 10 μm, suitably about 5 μm.

In some cases, the carrier may have a thickness of between about 0.010 mm to about 2.0 mm, suitably from about 0.015 mm, 0.02 mm, 0.05 mm or 0.1 mm to about 1.5 mm, 1.0 mm or 0.5 mm. Consumables

In another aspect of the present disclosure, there is provided a consumable for use in a non-flammable aerosol delivery device, the consumable comprising an aerosol generating composition, wherein the aerosol generating composition comprises an aerosol generating material as defined herein.

In some embodiments, the present disclosure relates to consumables that include an aerosol generating composition and are configured to be used with a non-flammable aerosol supply device. Such consumables are sometimes referred to as articles throughout the present disclosure.

The consumables may be used with any suitable non-flammable aerosol delivery device.

A consumable is an article containing or consisting of an aerosol generating composition, part or all of which is intended to be consumed by a user during use. A consumable may include one or more other components, such as an aerosol generating composition storage area, an aerosol generating composition transmission component, an aerosol generating area, a housing, a roll of paper, a nozzle, a filter and/or an aerosol modifier. A consumable may also include an aerosol generator, such as a heater, which emits heat to cause the aerosol generating composition to generate an aerosol during use. The heater may, for example, include a combustible material, a material that can be heated by electrical conduction, or a receptor.

A susceptor is a material that can be heated by passing it through a varying magnetic field (e.g., an alternating magnetic field). A susceptor can be a conductive material such that its penetration with a varying magnetic field causes inductive heating of the heating material. The heating material can be a magnetic material such that penetration of the heating material by a varying magnetic field causes hysteresis heating of the heating material. A susceptor can be both conductive and magnetic such that the susceptor can be heated by both heating mechanisms. A device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

Aerosol modifiers are substances configured to modify the generated aerosol, for example by changing the taste, flavor, acidity or another characteristic of the aerosol, typically located downstream of the aerosol generation region. Aerosol modifiers may be provided in an aerosol modifier release assembly that is operable to selectively release the aerosol modifier.

The aerosol modifier may be, for example, an additive or an absorbent. The aerosol modifier may, for example, include one or more of a flavoring agent, a coloring agent, water, and a carbon absorbent. The aerosol modifier may, for example, be a solid, a liquid, or a gel. The aerosol modifier may be in the form of a powder, a string, or a granule. The aerosol modifier may not contain a filter material.

An aerosol generator is a device configured to cause an aerosol to be generated from an aerosol generating composition. In some embodiments, the aerosol generator is a heater configured to subject the aerosol generating composition to thermal energy so as to release one or more volatiles from the aerosol generating composition to form an aerosol. In some embodiments, the aerosol generator is configured to cause an aerosol to be generated from the aerosol generating composition without heating. For example, the aerosol generator may be configured to subject the aerosol generating composition to one or more of vibration, pressurization, or electrostatic energy. Non-flammable aerosol supply system

In another aspect of the present disclosure, a non-flammable aerosol supply system is provided, which includes the consumables described herein and a non-flammable aerosol supply device.

According to the present disclosure, a "non-flammable" aerosol delivery system is a system that generates an aerosol composition for facilitating delivery of at least one substance to a user without burning or roasting the constituent aerosol delivery system (or components thereof).

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

In some embodiments, the non-flammable aerosol supply system is an aerosol generating composition heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.

In some embodiments, the non-flammable aerosol supply device is a heating or burning device.

In some embodiments, the non-flammable aerosol supply system is a hybrid system that uses a combination of aerosol generating components to generate aerosols, one or more of which can be heated. In some embodiments, the hybrid system includes an aerosol generating component described herein, which includes or consists of an aerosol generating material and an additional liquid or gel aerosol generating component.

In some embodiments, the non-flammable aerosol supply device is an electronic cigarette mixing device.

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

In some embodiments, a non-flammable aerosol supply system, such as a non-flammable aerosol supply device thereof, may include an energy source and a controller. For example, the energy source may be an electronic energy source or an exothermic energy source. In some embodiments, the exothermic energy source includes a carbon matrix that can be charged to distribute energy in the form of heat to an aerosol generating composition or a heat transfer material near the exothermic energy source.

In some embodiments, a non-flammable aerosol supply system, such as a non-flammable aerosol supply device thereof, may include an area for receiving consumables, an aerosol generator, an aerosol generating area, a housing, a nozzle, a filter and/or an aerosol modifier.

The non-flammable aerosol supply system or device may include a heater configured to heat but not burn the aerosol generating composition/aerosol generating material. In some cases, the heater may be a thin film resistive heater. In other cases, the heater may include an induction heater or the like. In other cases, the heater may be a combustible heat source or a chemical heat source that undergoes an exothermic reaction in use to generate heat.

In some cases, the heater may heat the aerosolizable material to between 120°C and 350°C during use, but without burning. In some cases, the heater may heat the aerosolizable material to between 140°C and 250°C during use, but without burning. In some cases, 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 solid is disposed between about 0.017 mm and 2.0 mm, suitably between about 0.1 mm and 1.0 mm from the heater. These minimum distances may in some cases reflect the thickness of the carrier supporting the aerosol generating material. In some cases, the surface of the aerosol generating material may be directly adjacent to the heater.

In some cases, the heater may be embedded in the aerosol generating composition/the aerosol generating material. In some such cases, the heater may be a resistive heater (having exposed contacts for connection to an electrical circuit). In other such cases, the heater may be a susceptor embedded in the aerosol generating composition that heats by induction.

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

In some cases, the aerosol supply system may be a heat-not-burn system. That is, it may contain solid materials (and no liquid aerosolizable materials). A heat-not-burn device is disclosed in WO 2015/062983 A2, which is incorporated herein by reference in its entirety.

In some cases, the non-flammable aerosol supply system may include an electronic cigarette mixing device. That is, it may include a solid aerosolizable material and a liquid aerosolizable material. The individual aerosolizable materials may be heated by separate heaters, the same heater, or in one case, the downstream aerosolizable material may be heated by hot aerosol generated from the upstream aerosolizable material. An electronic cigarette mixing device is disclosed in WO 2016/135331 A1, which is incorporated herein by reference in its entirety.

The consumable may alternatively be referred to herein as a cartridge. The consumable may be suitable for use with a THP, an e-cigarette mixing device, or other aerosol generating device. In some cases, the consumable may additionally include a filter and/or a cooling element, as described above. In some cases, the consumable may be surrounded by a packaging material (e.g., paper).

The consumable may additionally include ventilation holes. These may be provided in the side walls of the article. In some cases, 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 may mix with the heated volatile components, thereby cooling the aerosol.

Aeration is the process of enhancing the visible heated volatile components generated from the article when heated in use. The heated volatile components become visible by cooling the heated volatile components so that supersaturation of the heated volatile components occurs. The heated volatile components then undergo droplet formation, otherwise known as nucleation, and the size of the final heated volatile component aerosol particles increases by further condensation of the heated volatile components and coalescence of newly formed droplets of the heated volatile components.

In some cases, the ratio of cold air to the sum of heated volatile components and cold air, known as the ventilation ratio, is at least 15%. A ventilation ratio of 15% enables the heated volatile components to become visible by the method described above. The visibility of the heated volatile components enables the user to recognize that the volatile components have been produced and enhances the sensory experience of the smoking experience.

In another example, the ventilation ratio is between 50% and 85% to provide additional cooling for heated volatile components. In some cases, the ventilation ratio may be at least 60% or 65%.

Referring to Figures 1 and 2, a partially cutaway cross-sectional view and a perspective view of one example of an object consumable 101 ("object") are shown. Object 101 is suitable for use with a device having a power source and a heater. The object 101 of this embodiment is particularly suitable for use with the device 1 shown in Figures 5 to 7 described below. When in use, the object 101 is removably inserted into the device shown in Figure 5 at the insertion point 20 of the device 1.

The object 101 of one example is in the form of a substantially cylindrical rod, which includes a body of an aerosol generating composition 103 in the form of a rod and a filter assembly 105. The aerosol generating composition includes an aerosol generating material as described herein. In some embodiments, it may be included in the form of a sheet. In some embodiments, it may be included in the form of a shredded material. In some embodiments, the aerosol generating material as described herein may be incorporated in both sheet form and shredded form.

The filter assembly 105 includes three sections: a cooling section 107, a filter section 109, and an end section 111. The object 101 has a first end 113, also referred to as an end or proximal end, and a second end 115, also referred to as a distal end. The body of the aerosol generating composition 103 is positioned toward the distal end 115 of the object 101. In one example, the cooling section 107 is positioned adjacent to the body of the aerosol generating composition 103 and between the body of the aerosol generating composition 103 and the filter section 109, so that the cooling section 107 is in an adjacent relationship with the aerosol generating composition 103 and the filter section 103. In other examples, there may be a space between the body of the aerosol generating composition 103 and the cooling section 107 and between the body of the aerosol generating composition 103 and the filter section 109. The filter section 109 is positioned between the cooling section 107 and the mouth section 111. The mouth section 111 is positioned toward the proximal end 113 of the object 101, adjacent to the filter section 109. In one example, the filter section 109 is in an adjacent relationship to the mouth section 111. In one embodiment, the total length of the filter assembly 105 is between 37 mm and 45 mm, and more preferably, the total length of the filter assembly 105 is 41 mm.

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

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

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

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

In one example, the cooling section 107 is an annular tube and is positioned around and defines an air gap within the cooling section. The air gap provides a chamber for the heated volatile components generated by the body of the aerosol generating composition 103 to flow. The cooling section 107 is hollow to provide a chamber for aerosol accumulation, while also being sufficiently rigid to withstand the axial compression forces and bending moments that may be generated during manufacturing and during use when inserting the object 101 into the device 1. In one example, the thickness of the wall of the cooling section 107 is about 0.29 mm.

The cooling section 107 provides a physical displacement between the aerosol generating composition 103 and the filter section 109. The physical displacement provided by the cooling section 107 will provide a thermal gradient across the length of the cooling section 107. In one example, the cooling section 107 is configured to provide a temperature difference of at least 40 degrees Celsius between the heated volatile components entering a first end of the cooling section 107 and the heated volatile components leaving a second end of the cooling section 107. In one example, the cooling section 107 is configured to provide a temperature difference of at least 60 degrees Celsius between the heated volatile components entering the first end of the cooling section 107 and the heated volatile components exiting the second end of the cooling section 107. This temperature difference across the length of the cooling element 107 protects the temperature sensitive filter section 109 from the high temperature of the aerosol generating composition 103 when heated by the device 1. If no physical displacement is provided between the filter section 109 and the body of the aerosol generating composition 103 and the heating element of the device 1, the temperature sensitive filter section 109 may be damaged during use and thus fail to effectively perform its required function.

In one example, the length of the cooling section 107 is at least 15 mm. In one example, the length of the cooling section 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 section 107 is made of paper, meaning that the cooling section is composed of a material that will not generate compounds of concern, such as toxic compounds, when adjacent to the heater of the device 1 during use. In one example, the cooling section 107 is made of a spirally wound paper tube that provides a hollow interior chamber while also maintaining mechanical rigidity. The spirally wound paper tube is able to meet the stringent dimensional accuracy requirements of the high speed manufacturing process with respect to tube length, outer diameter, roundness, and straightness.

In another example, the cooling section 107 is a groove built from a rigid filter nozzle web or tipping paper. The rigid filter nozzle web or tipping paper is manufactured to have sufficient rigidity to withstand the axial compression forces and bending moments that may occur during manufacturing and during use when inserting the object 101 into the device 1.

The filter section 109 can be formed of any filter material sufficient to remove one or more volatile compounds from the heated volatile components of the aerosol generating composition. In one example, the filter section 109 is made of a monoacetate material, such as cellulose acetate. The filter section 109 provides cooling and irritation reduction of the heated volatile components without consuming the amount of the heated volatile components to a level that is unsatisfactory for the user.

In some embodiments, a capsule (not shown) may be disposed in the filter segment 109. It may be substantially centrally located in the filter segment 109, both across the diameter of the filter segment 109 and along the length of the filter segment 109. In other cases, it may be offset in one or more dimensions. The capsule, in some cases, if present, may contain volatile components, such as flavoring agents or aerosol forming agent materials.

The density of the cellulose acetate tow material of filter segment 109 controls the pressure drop across filter segment 109, which in turn controls the resistance to suction of object 101. Therefore, the choice of material for filter segment 109 is critical in controlling the resistance to suction of object 101. In addition, the filter segment performs a filtering function in object 101.

In one example, filter segment 109 is made of 8Y15 grade filter tow material, which provides a filtering effect on the heated volatile materials while also reducing the size of condensed aerosol droplets generated by the heated volatile materials.

The presence of the filter section 109 provides an insulating effect by providing further cooling for the heated volatile components leaving the cooling section 107. This further cooling effect reduces the contact temperature of the user's lips on the surface of the filter section 109.

In one example, the length of the filter section 109 is between 6 mm and 10 mm, suitably 8 mm.

The mouth end section 111 is an annular tube and is positioned around and defines an air gap within the mouth end section 111. The air gap provides a chamber for the heated volatile components flowing out of the filter section 109. The mouth end section 111 is hollow to provide a chamber for aerosol accumulation, while also being sufficiently rigid to withstand axial compression forces and bending moments that may be generated during manufacturing and during insertion of objects into the device 1 during use. In one example, the thickness of the wall of the mouth end section 111 is about 0.29 mm. In one example, the length of the mouth end section 111 is between 6 mm and 10 mm, suitably 8 mm.

The mouth section 111 can be manufactured from a spirally wound paper tube that provides a hollow interior chamber while also maintaining critical mechanical rigidity. Spiral wound paper tubes are able to meet the stringent dimensional accuracy requirements of high speed manufacturing processes with respect to tube length, outer diameter, roundness, and straightness.

The mouth section 111 provides the function of preventing any liquid condensate accumulated at the outlet of the filter section 109 from directly contacting the user.

It should be understood that in one example, the port section 111 and the cooling section 107 can be formed by a single tube and the filter section 109 is positioned within this tube, separating the port section 111 from the cooling section 107.

3 and 4, there are shown partial cutaway cross-section and perspective views of an example of an article 301. The symbols shown in FIGS. 3 and 4 are equivalent to the symbols shown in FIGS. 1 and 2, but with an increment of 200.

In the example of the object 301 shown in FIGS. 3 and 4 , a ventilation region 317 is provided in the object 301 to enable air to flow from the exterior of the object 301 to the interior of the object 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 object 301. The ventilation holes can be positioned in the cooling section 307 to facilitate cooling of the object 301. In one example, the ventilation region 317 includes one or more rows of holes, and preferably, in a cross-section substantially perpendicular to the longitudinal axis of the object 301, the rows of holes are arranged circumferentially around the object 301.

In one example, there are between one and four rows of vents to provide ventilation of the object 301. Each row of vents may have between 12 and 36 vents 317. The diameter of the vents 317 may be, for example, between 100 and 500 μm. In one example, the axial spacing between rows of vents 317 is between 0.25 mm and 0.75 mm, suitably 0.5 mm.

In one example, the vent holes 317 are of uniform size. In another example, the vent holes 317 are of different sizes. The vent holes can be made using any suitable technique, such as one or more of the following techniques: laser technology, mechanical perforation of the cooling section 307, or pre-perforation before the cooling section 307 is formed into the object 301. The vent holes 317 are positioned to provide effective cooling for the object 301.

In one example, the row of vent holes 317 is located at least 11 mm from the proximal end 313 of the object, suitably between 17 mm and 20 mm from the proximal end 313 of the object 301. The position of the vent holes 317 is located so that the user does not block the vent holes 317 when the object 301 is in use.

As can be seen in Figures 6 and 7, when the object 301 is fully inserted into the device 1, multiple rows of vent holes are provided between 17 mm and 20 mm from the proximal end 313 of the object 301 so that the vent holes 317 can be located outside the device 1. By locating the vent holes outside the device, unheated air can enter the object 301 from outside the device 1 through the vent holes to help cool the object 301.

The length of the cooling section 307 is such that when the object 301 is fully inserted into the device 1, the cooling section 307 will be partially inserted into the device 1. The length of the cooling section 307 provides a first function of providing a physical gap between the heater arrangement and the thermistor arrangement 309 of the device 1, and a second function of enabling the vent 317 to be located in the cooling section while also being located outside the device 1 when the object 301 is fully inserted into the device 1. As can be seen from Figures 6 and 7, the majority of the cooling element 307 is located within the device 1. However, a portion of the cooling element 307 extends out of the device 1. The vent 317 is located in this portion of the cooling element 307 that extends out of the device 1.

Referring now to Figures 5 to 7 in more detail, there is shown an example of a device 1 configured to heat an aerosol generating composition to volatilize at least one component of the aerosol generating composition, typically to form an inhalable aerosol. Device 1 is a heating device that releases compounds by heating rather than burning the aerosol generating composition.

The first end 3 is sometimes referred to herein as the mouth or proximal end 3 of the device 1, and the 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 turned on and off as desired by the user.

The device 1 includes a housing 9 for locating and protecting the various internal components of the device 1. In the illustrated example, the housing 9 includes a single-body sleeve 11 that surrounds the perimeter of the device 1, the single-body sleeve terminating with a top panel 17 that generally defines the "top" of the device 1 and terminating with a bottom panel 19 that generally defines the "bottom" of the device 1. In another example, in addition to the top panel 17 and the bottom panel 19, the housing includes a front panel, a rear panel, and a pair of opposing side panels.

The top panel 17 and/or the bottom panel 19 may be removably secured to the single body sleeve 11 to allow easy access to the interior of the device 1, or may be "permanently" secured to the single body sleeve 11, for example to prevent a user from entering the interior of the device 1. In one example, the panels 17 and 19 are made of a plastic material, including glass-filled nylon formed, for example, by injection molding, and the single body sleeve 11 is made of aluminum, although other materials and other manufacturing methods 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 an object 101 , 301 comprising an aerosol generating composition is inserted into and removed from the device 1 by a user in use.

The housing 9 has positioned or secured therein a heater arrangement 23, a control circuit system 25, and a power supply 27. In this example, the heater arrangement 23, the control circuit system 25, and the power supply 27 are laterally adjacent (i.e., adjacent when viewed from one end), and the control circuit system 25 is generally positioned between the heater arrangement 23 and the power supply 27, although other positions are possible.

The control circuitry 25 may include a controller, such as a microprocessor arrangement, assembled and configured to control the heating of the aerosol generating composition in the object 101, 301, as further discussed 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, lithium-ion batteries, nickel batteries (such as nickel-cadmium batteries), alkaline batteries, and/or the like. The battery 27 is electrically coupled to the heater arrangement 23 to supply power to heat the aerosol-generating composition in the article when necessary and under the control of the control circuit system 25 (as discussed, to volatilize the aerosol-generating composition without causing the aerosol-generating composition to burn).

An advantage of locating the power source 27 laterally adjacent to the heater arrangement 23 is that a physically large power source 25 can be used without causing the overall length of the device 1 to be excessive. As will be appreciated, in general, a physically large power source 25 has a higher capacity (i.e., the total electrical energy that can be supplied, usually measured in ampere-hours or the like), and therefore the battery life of the device 1 can be longer.

In one example, the heater arrangement 23 is generally in the form of a hollow cylindrical tube with a hollow internal heating chamber 29 into which, in use, the article 101, 301 comprising the composition generating the aerosol is inserted for heating. Different configurations of the heater arrangement 23 are possible. For example, the heater arrangement 23 may comprise a single heating element or may be formed by a plurality of heating elements aligned along the longitudinal axis of the heater arrangement 23. The or each heating element may be annular or tubular, or at least partially annular or partially tubular around its circumference. In one example, the or each heating element may be a thin film heater. In another example, the or each heating element may be made of a ceramic material. Examples of suitable ceramic materials include alumina and aluminum nitride and silicon nitride ceramics, which can be layered and sintered. Other heating arrangements are possible, including inductive heating, such as heating by emitting infrared radiation, infrared heater elements, or resistive heating elements formed by, for example, resistive electrical windings.

In a specific example, the heater arrangement 23 is supported by a stainless steel support tube and includes a polyimide heating element. The heater arrangement 23 is sized so that when the object 101, 301 is inserted into the device 1, substantially the entire body of the aerosol generating composition 103, 303 of the object 101, 301 is inserted into the heater arrangement 23.

The or each heating element may be configured so that selected regions of the aerosol generating composition can be heated independently, for example sequentially (over time, as discussed above) or together (simultaneously) as required.

In this example, the heater arrangement 23 is surrounded by a thermal insulator 31 along at least a portion of its length. The insulator 31 helps reduce the heat transferred from the heater arrangement 23 to the exterior of the device 1. This helps to reduce the power requirements of the heater arrangement 23 because it reduces heat losses overall. 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 can be a double-walled sleeve that provides a low pressure region between the two walls of the sleeve. That is, the insulator 31 can be, for example, a "vacuum" tube, that is, a tube that has been at least partially evacuated to minimize heat transfer by conduction and/or convection. Other configurations of the insulator 31 are possible, including the use of insulating materials, including, for example, suitable foam-type materials, in addition to or in place of the double-walled sleeve.

The housing 9 may further include various internal support structures 37 for supporting all internal components and the heating arrangement 23.

The apparatus 1 further comprises a collar 33 and a generally tubular chamber 35 extending around the opening 20 and protruding from the opening to the interior of the housing 9, the tubular chamber being located between the collar 33 and one end of the vacuum sleeve 31. The chamber 35 further comprises a cooling structure 35f, which in this example comprises a plurality of cooling fins 35f spaced along the outer surface of the chamber 35, and each cooling fin is arranged circumferentially around the outer surface of the chamber 35. When inserted into the apparatus 1 over at least a portion of the length of the hollow chamber 35, an air gap 36 exists between the hollow chamber 35 and the object 101, 301. Over at least a portion of the cooling section 307, the air gap 36 surrounds the entire circumference of the object 101, 301.

The collar 33 includes a plurality of ridges 60 that are circumferentially arranged around the outer periphery of the opening 20 and protrude into the opening 20. The ridges 60 occupy space within the opening 20 so that the opening span of the opening 20 at the location of the ridges 60 is smaller than the opening span of the opening 20 at a location without the ridges 60. The ridges 60 are configured to engage with the object 101, 301 inserted into the device to assist in securing it within the device 1. The open space (not shown) defined by the adjacent ridges 60 and the object 101, 301 forms a ventilation path around the outside of the object 101, 301. These ventilation paths allow hot vapor that has escaped from the objects 101, 301 to leave the device 1, and allow cooling air to flow into the device 1 around the objects 101, 301 in the air gap 36.

In operation, the object 101, 301 is removably inserted into the insertion point 20 of the device 1, as shown in Figures 5 to 7. With particular reference to Figure 6, in one example, the bulk of the aerosol generating composition 103, 303 at the distal end 115, 315 of the object 101, 301 is entirely housed within the heater arrangement 23 of the device 1. The proximal end 113, 313 of the object 101, 301 extends from the device 1 and serves as a mouthpiece assembly for the user.

In operation, the heater arrangement 23 will heat the object 101, 301 to volatilize at least one component of the aerosol generating composition from the body of the aerosol generating composition 103, 303.

The primary flow path of the heated volatile components from the main body of the aerosol generating composition 103, 303 is axially through the object 101, 301, through the chamber inside the cooling section 107, 307, through the filter section 109, 309, and through the mouth section 111, 313 to the user. In one example, the temperature of the heated volatile components generated by the main body of the aerosol generating composition is between 60°C and 250°C, which may be higher than the acceptable inhalation temperature of the user. As the heated volatile components travel through the cooling section 107 , 307 , the heated volatile components will cool and some of the volatile components will condense on the interior surfaces of the cooling section 107 , 307 .

In the example of the article 301 shown in Figures 3 and 4, cooling air will be able to enter the cooling section 307 through the vents 317 formed in the cooling section 307. This cooling air will mix with the heated volatile components to provide additional cooling for the heated volatile components. Method of Producing Aerosol Generating Materials

Another aspect of the present invention provides a method for preparing the aerosol generating material described herein. The method may further include: (a) providing a slurry comprising an aerosol forming agent material, a first binder (which is galactomannan gum), a second binder (which is hydroxypropyl methylcellulose), a filler and a solvent; (b) aerating the slurry; (c) forming a layer of aerated slurry; and (d) drying the slurry to form the aerosol generating material.

The step (b) of aerating the slurry may comprise mixing the slurry under high shear conditions.

The step (a) of providing a slurry may comprise mixing the slurry under high shear conditions such that step (b) is part of step (a). The step (b) of aerating the slurry may comprise bubbling a gas through the slurry

The disclosure herein about the components of the aerosol generating material is equally applicable to the slurry. The slurry may contain these components in any proportion given herein with respect to the composition of the aerosol generating material.

When the aerosol generating material comprises an additional binder comprising alginate and/or pectin, the slurry may further comprise a setting agent and/or a setting agent may be applied to the slurry. In this case, the method may further comprise a step of setting the slurry. In some embodiments, forming a layer of slurry and/or setting the slurry and/or drying the slurry occur at least partially simultaneously (e.g., during electrospraying). In some embodiments, the steps of forming a layer of slurry, setting the slurry with any setting agent, and drying the slurry occur in this order.

(c) forming a layer of slurry generally comprises spraying, pouring or extruding the slurry. In an embodiment, the slurry layer is formed by pouring the slurry.

In some examples, the slurry is applied to the support. The layer can be formed on the support.

In examples, drying (d) removes from about 50 wt%, 60 wt%, 70 wt%, 80 wt%, or 90 wt% to about 80 wt%, 90 wt%, or 95 wt% (on a wet weight basis, WWB) of water in the slurry.

In an example, drying (d) reduces the thickness of the cast material by at least 80%, suitably 85% or 87%. For example, if the slurry is cast at a thickness of 2 mm, the resulting dried aerosol-generated material may have a thickness of 0.2 mm.

In an embodiment, the dried aerosol generating material forms a sheet or layer having a thickness of about 0.015 mm to about 1.0 mm. Suitably, the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm, such as 0.05-0.3 or 0.15-0.3 mm. A material having a thickness of 0.2 mm may be particularly suitable.

Another aspect of the present invention provides a method for making an aerosol generating composition (hereinafter referred to as the second method), wherein the aerosol generating composition comprises an aerosol generating material as described herein. The method may include providing an aerosol generating material and combining the aerosol generating material and a tobacco material to provide the aerosol generating composition.

In some cases, the aerosol generating composition can include an aerosol former material in an amount of about 5 to about 30 wt % of the aerosol generating composition on a dry weight basis.

The second method generally comprises providing an aerosol generating material as described above, providing a tobacco material as described above, and combining the aerosol generating material and the tobacco material in a ratio generally to provide an aerosol generating composition having an aerosol former material content of from about 5 to about 30 wt % of the aerosol generating composition.

In an example, the aerosol generating material is provided as a shredded material. In a specific example, providing the aerosol generating material comprises shredding a sheet of the aerosol generating material to provide the aerosol generating material as a shredded material. In an example, the tobacco material is finely chopped, and combining the aerosol generating material and the tobacco material comprises mixing the shredded material of the aerosol generating material with the finely chopped tobacco material.

The slurry itself is an aspect of the present invention. In some embodiments, the slurry solvent consists essentially of or consists of water. In some embodiments, the slurry comprises about 50 wt%, 60 wt%, 70 wt%, 80 wt%, or 90 wt% solvent (WWB). EXAMPLES

Produce an aerosol generating material having the following composition.

The wood pulp is partially refined with water under high shear conditions. Binders and foaming agents are added, followed by glycerol and cellulose. The mixture is sheared at a high shear rate and cast to a height of 1 mm. The mixture has a solid content (i.e. dry material) of 20% and a water content of 80%.

Unless otherwise specified, percentages are quoted on a dry weight basis. Filling values, tack and tensile strength of the aerosol generating materials were measured as described above. Table 1 - 50% Glycerol Sample Amount of each component (wt%) Sample Locust Bean Gum HPMC glycerin CMC Powdered cellulose Wood pulp Control group 1 0 0 50 7 36 7 Example 1 (Comparison) 0 7 50 0 36 7 Example 2 (Comparison) 5 0 50 5.3 34.3 5.3 Embodiment 3 2 5 50 0 36 7

Figure 8 shows the results of the filling values of the materials listed in Table 1. As can be seen in Figure 8, unexpectedly, the filling value of Example 3 containing a total of 7 wt.% HPMC and galactomannan gum (locust bean gum) is higher than the filling values of Comparative Example 1 containing 7 wt.% HPMC and Comparative Example 2 containing 5 wt.% locust bean gum.

Thus, unexpectedly, the material containing the combination of the binders HPMC and galactomannan gum showed higher filling values compared to the material containing only one of these binders. Table 2 - 35% Glycerol Sample Amount of each component (wt%) Sample Locust Bean Gum HPMC glycerin CMC Powdered cellulose Wood pulp Control group 2 0 0 35 9 47 9 Example 4 (Comparison) 0 9 35 0 47 9 Example 5 (Comparison) 5 0 35 7.3 45.3 7.3 Embodiment 6 2.6 6.4 35 0 47 9 Embodiment 7 3.9 5.1 35 0 47 9

FIG9 shows the results of the filling values of the materials listed in Table 1. As can be seen from FIG9 , the measured filling values of Examples 6 and 7 are unexpectedly higher than the measured filling values of Comparative Examples 4 and 5.

Therefore, the results shown in Figure 9 further confirm that the combination of the binders HPMC and galactomannan gum unexpectedly increases the filling value of the material compared to materials containing only one of these binders.

The tensile strength and adhesiveness results for some of the above materials are shown in Figures 10-13.

Both Figures 10 and 11 show that Comparative Examples 1 and 4 containing only HPMC as a binder have lower tensile strength than Comparative Examples 2 and 5 containing only locust bean gum as a binder.

Figures 12 and 13 also show that Comparative Examples 1 and 4 containing only HPMC as a binder have lower adhesiveness measurements than Comparative Examples 2 and 5 containing only locust bean gum as a binder.

These data show that using galactomannan gums such as locust bean gum as an adhesive can provide higher tensile strength, while using HPMC as an adhesive can provide more ideal adhesion. By combining the two adhesives, a good balance between tensile strength and adhesion can be achieved.

Unless expressly stated otherwise, all weight percentages (denoted as wt%) described herein are calculated on a dry weight basis (DWB). All weight ratios are also calculated on a dry weight basis. Weights given on a dry weight basis refer to all extracts or slurries or materials other than water, and may include components that are themselves liquid at room temperature and pressure, such as glycerol. In contrast, weight percentages given on a wet weight basis (WWB) refer to all components, including water.

For the avoidance of doubt, in this specification, when the term "comprising" is used to define the present invention or features of the present invention, it is also disclosed that the term "consisting essentially of" or "consisting of" may be used instead of "comprising" to define the embodiments of the present invention or features. Referring to a material "comprising" certain features means that those features are included in the material, contained in the material, or contained in the material.

The above embodiments should be understood as illustrative examples of the present invention. It should be understood that any feature described with respect to any embodiment, aspect or example may be used alone or in combination with other features described, or may be used in combination with one or more features of any other of the embodiments, aspects or examples or any combination of any other of the embodiments, aspects or examples. Furthermore, equivalents and modifications not described above may also be adopted without departing from the scope of the present invention as defined in the attached patent claims.

The various embodiments described herein are presented only to assist in understanding and teach the claimed features. These embodiments are provided only as representative samples of embodiments and are not exhaustive and/or exclusive. It should be understood that the advantages, embodiments, examples, functions, features, structures and/or other aspects described herein are not intended to be considered as limitations on the scope of the invention as defined by the scope of the patent application, or limitations on the equivalent content of the scope of the patent application, and other embodiments may be used and may be modified without departing from the claimed scope of the invention. The various embodiments of the present invention may suitably include, consist of, or consist essentially of appropriate combinations of disclosed elements, components, features, parts, steps, components, etc. other than those combinations specifically described herein. In addition, the present disclosure may include other inventions that are not currently claimed but may be claimed in the future.

1: device 3: first end, mouth end, proximal end 5: second end, distal end 7: on/off button 9: housing 11: single body sleeve 17: top panel, panel 19: bottom panel, panel 20: insertion point, opening 23: heater configuration, heating configuration 25: control circuit system 27: power supply, battery 29: hollow internal heating chamber 31: thermal insulator, insulator, vacuum sleeve 33: collar 35: tubular chamber, hollow chamber, chamber 35f: cooling structure, cooling fin 36: air gap 37: internal support structure 60: spine 101: object consumable, object 103: aerosol generating composition 105: filter assembly 107: cooling section, cooling element 109: filter section, temperature sensitive filter section 111: mouth section 113: first end, mouth, proximal end 115: second end, distal end 301: object 303: aerosol generating composition 307: cooling section, cooling element 309: temperature sensitive filter configuration, filter section 313: proximal end, mouth section 315: distal end 317: ventilation area, vent

FIG. 1 shows a cross-sectional view of an example of an aerosol-generated object.

FIG. 2 shows a perspective view of the object in FIG. 1 .

FIG. 3 shows a cross-sectional elevation view of an example of an aerosol-generated bioparticle.

FIG. 4 shows a perspective view of the object of FIG. 3 .

FIG. 5 shows a perspective view of an example of a non-flammable aerosol supply system.

FIG6 shows a cross-sectional view of an example of a non-flammable aerosol supply system.

FIG. 7 shows a perspective view of an example of a non-flammable aerosol supply system.

Figures 8-13 show the measured properties of various aerosol generating materials, such as filling value, adhesiveness, and tensile strength.

101: Object consumables, objects

103: Aerosol generating composition

105:Filter assembly

107: Cooling section, cooling element

109: Filter section, temperature sensitive filter section

111: Port section

113: first end, mouth end, proximal end

115: Second end, remote end

Claims (25)

An aerosol generating material comprises: (i) an aerosol former material; (ii) a first binder, which is galactomannan gum; (iii) a second binder, which is hydroxypropyl methylcellulose; and (iv) a filler. The aerosol generating material of claim 1, wherein the galactomannan gum is locust bean gum. An aerosol generating material as claimed in any preceding claim, wherein the aerosol generating material further comprises tartaric acid. The aerosol generating material of claim 3, wherein the aerosol generating material comprises from about 1 to about 5 wt % of tartaric acid. An aerosol-generating material as claimed in any preceding claim, wherein the aerosol-generating material comprises from about 1 to about 10 wt % of the first binder. An aerosol-generating material as claimed in any preceding claim, wherein the aerosol-generating material comprises from about 1 to about 10 wt % of the second binder. An aerosol-generating material as claimed in any preceding claim, wherein the total amount of the first and second binders in the aerosol-generating material is from about 2 to about 15 wt % of the aerosol-generating material. An aerosol generating material as claimed in any preceding claim, wherein the aerosol generating material has a filling value of at least about 3 cm ³ /g or at least about 4 cm ³ /g. An aerosol generating material as claimed in any preceding claim, wherein the aerosol generating material has a tensile strength of at least about 5 N/15 mm. An aerosol generating material as claimed in any preceding claim, wherein the aerosol generating material has a viscosity of less than about 0.2 N. An aerosol generating material as claimed in any preceding claim, wherein the aerosol former material comprises one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, tetratetrol, meso-tetratetrol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, glyceryl triacetate, a mixture of diacetates, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid and propylene carbonate. An aerosol generating material as claimed in any preceding claim, wherein the aerosol generating material comprises from about 1 to about 60 wt % of an aerosol former material. An aerosol generating material as claimed in any preceding claim, wherein the aerosol generating material comprises from about 10 to about 60 wt % of an aerosol former material. An aerosol generating material as claimed in any preceding claim, wherein the aerosol generating material comprises from about 20 to about 40 wt % of an aerosol former material. An aerosol generating material as claimed in any preceding claim, wherein the aerosol generating material comprises from about 40 to about 60 wt % of an aerosol former material. An aerosol generating material as claimed in any preceding claim, wherein the filler comprises wood pulp, cellulose and/or cellulose derivatives, such as wood pulp and/or microcrystalline cellulose. An aerosol generating material as claimed in any preceding claim, wherein the aerosol generating material comprises from about 1 to about 80 wt % filler, such as from about 30 to about 70 wt % filler, such as from about 40 to about 60 wt % filler. An aerosol generating material as claimed in any preceding claim, wherein the aerosol generating material does not contain carboxymethyl cellulose or alginate, and/or does not contain an active substance, and/or does not contain tobacco material. An aerosol generating composition comprising an aerosol generating material as claimed in any of the preceding claims. A consumable for use in a non-flammable aerosol supply device, the consumable comprising an aerosol generating composition as claimed in claim 19. A non-flammable aerosol supply system, comprising a consumable as claimed in claim 20 and a non-flammable aerosol supply device, wherein when the consumable is used together with the non-flammable aerosol supply device, the non-flammable aerosol supply device comprises an aerosol generating device configured to generate aerosol from the consumable. A method for generating an aerosol using a non-flammable aerosol supply system as claimed in claim 21, the method comprising heating the aerosol generating material to a temperature less than 350°C. A method of forming an aerosol generating material as claimed in any one of claims 1 to 18, the method comprising: (a) providing a slurry comprising: (i) an aerosol forming agent material; (ii) a first binder which is galactomannan; (iii) a second binder which is hydroxypropyl methylcellulose; (iv) a filler; and (v) a solvent; (b) aerating the slurry; (c) forming a layer of the aerated slurry; (d) drying the slurry to form the aerosol generating material. The method of claim 23, wherein step (b) comprises mixing the slurry under high shear conditions and/or bubbling a gas through the slurry. The method of claim 23 or 24, wherein step (a) of providing the slurry comprises mixing the slurry under high shear conditions so that step (b) is part of step (a).