JP7618644B2 - Aerosol Generation - Google Patents

Description

The present invention relates to aerosol generation.

background

Smoking articles, such as cigarettes and cigars, burn tobacco to produce tobacco smoke during use. Alternatives to these types of articles release inhalable aerosols or vapors by releasing compounds from a substrate material through heating without combustion. These alternatives are sometimes referred to as non-combustion smoking articles or aerosol-generating assemblies.

One example of such a product is a heating device that releases compounds by heating, but not burning, a solid aerosolizable material, which in some cases may contain tobacco material. Upon heating, at least one component of the material is volatilized, typically forming an inhalable aerosol. These products are sometimes referred to as non-combustion heating devices, tobacco heating devices, or tobacco heating products. A wide variety of configurations are known for volatilizing at least one component of a solid aerosolizable material.

Another known type of aerosol generating assembly is the electronic cigarette or e-cigarette. In these devices, a liquid or gel aerosol generating material is heated without combustion. These devices vaporize one component of the material to form an inhalable vapor or aerosol. The liquid or gel material may contain nicotine.

Another example is an e-cigarette/tobacco heating product hybrid device, also known as an electronic cigarette hybrid device. These hybrid devices contain a liquid source (which may or may not contain nicotine) that is vaporized upon heating to produce an inhalable vapor or aerosol. The device further contains a solid aerosolizable material (which may or may not contain tobacco material), the components of which are entrained in the inhalable vapor or aerosol to produce the inhalation medium.

overview

A first aspect of the present invention provides an aerosol product article for use in an aerosol generating assembly, the article comprising an aerosol generating substrate comprising an aerosol generating material, the aerosol generating material being solid and comprising starch and a plasticizer, the amount of plasticizer being between about 5% and 70% by weight of the starch.

A second aspect of the invention provides an aerosol generating assembly comprising an aerosol product article according to the first aspect and a heater configured to heat but not combust the aerosol generating material.

A third aspect of the present invention is a method for producing a composition comprising the steps of:
A plasticizer in an amount of about 5% to 70% by weight of the starch;
A fragrance or fragrance ingredient derived from a plant;
The present invention provides a starch matrix material comprising:

A fourth aspect of the invention provides a kit comprising an aerosol product article according to the first aspect and a device configured to contain the article in use, the device comprising a heater configured to heat but not combust the aerosol generating material in use.

A fifth aspect of the present invention provides a method of making an aerosol product according to the first aspect, comprising the steps of:
(i) mixing the components of an aerosol-generating material into a slurry, heating and stirring the slurry to gel, casting the gel, and drying by heating to form an aerosol-generating material;
(ii) incorporating the aerosol-forming material into an aerosol product;
The present invention provides a method comprising:

The present invention also provides
Starch,
A plasticizer in an amount of about 5% to 70% by weight of the starch;
A fragrance or fragrance ingredient derived from a plant;
Water,
A slurry comprising:

Preferably, the weight ratio of water to the total weight of other ingredients is about 10:1 to 20:1.

The present invention also provides
a starch; and a plasticizer in an amount of about 5% to 70% by weight of the starch;
a powdered tobacco material having an average particle diameter of less than about 250 μm in an amount of about 40% to 300% by weight of the starch;
Water,
wherein the weight ratio of water to the total weight of the other ingredients is about 10:1 to 20:1.

The present invention also provides
Starch,
A plasticizer in an amount of about 5% to 70% by weight of the starch;
an aqueous tobacco extract;
wherein the weight ratio of the aqueous tobacco extract to the total weight of the other ingredients is about 10:1 to 20:1.

A further aspect of the present invention is
(i) a wrapping material for a smoking article or an aerosol product, the wrapping material comprising a starch matrix and a plasticizer, the amount of the plasticizer being about 5% to 30% by weight of the starch; and (ii) a filter for a smoking article or an aerosol product, the filter comprising a starch matrix and a plasticizer, the amount of the plasticizer being about 5% to 15% by weight of the starch.

The present invention also provides an article comprising the above-mentioned wrapping material and/or filter.

Further aspects, features and advantages of the present invention will become apparent from the following description, given by way of example only, with reference to the accompanying drawings. Features described in this specification in relation to one aspect are expressly disclosed in combination with other aspects of the invention, insofar as they are compatible.

FIG. 1 is a cross-sectional view of an example of an aerosol product. FIG. 2 is a perspective view of the article of FIG. 1 . FIG. 2 is a cross-sectional elevation view of an example of an aerosol product. FIG. 4 is a perspective view of the article of FIG. FIG. 1 is a perspective view of an example of an aerosol generation assembly. FIG. 1 is a cross-sectional view of an example of an aerosol generation assembly. FIG. 1 is a perspective view of an example of an aerosol generation assembly.

Detailed Description

The aerosol-forming materials described herein are "solids." However, the aerosol-forming materials may be solids that retain some fluid, such as a liquid. The solid may be a gel. This is sometimes referred to as a "dry gel." This is also sometimes referred to as a "starch matrix."

As described above, the present invention provides an aerosol product article for use in an aerosol generating assembly, the article comprising an aerosol generating substrate comprising an aerosol generating material, the aerosol generating material being solid and comprising starch and a plasticizer, the amount of plasticizer being between about 5% and 70% by weight of the starch.

The inventors have found that a material having this composition can be effectively heated to produce an inhalable aerosol.

Starch forms a helical structure within which small molecules such as flavors and fragrances can bind. However, in order to release these molecules, the helix must be heated to unwind. The aerosol-generating materials described herein are formed by heating and melting starch and mixing it with a plasticizer, which becomes embedded within the starch. When the starch is then cooled, retrogradation (reorganization into a crystalline helical form) is inhibited by the glycerol, resulting in an irregular starch matrix to which small molecules can bind. The release temperature of these small molecules is lower than that of the regular crystalline structure.

The inventors have established that such starch matrix materials (including the claimed plasticizers) are suitable for use as aerosol generating materials in non-combustion smoking articles.

Any starch may be used in the present invention. Preferably, the starch may be a soluble starch, preferably a soluble unmodified starch. Preferably, the starch may be from a gluten-free product. The starch may include potato starch. This material is readily available. The inventors have established that the use of starch as a matrix material is preferred over other materials such as alginate and pectin, because these other ingredients require the addition of a stiffening agent (e.g., a calcium source) to form the matrix, whereas starch does not require such additional agents. Alginate and pectin also contribute to the dispersal of flavors/aromas in the generated aerosol, and it has been found that the use of starch as a matrix material reduces this effect. Starch also has a higher loading capacity. Starch materials are also typically less sticky than comparable alginate or pectin materials, making them easier to manufacture and handle.

The amount of plasticizer is about 5% to 70% by weight of the starch. Preferably, the amount of plasticizer may be about 5%, 10%, 15% or 20% to about 70%, 60% or 50% by weight of the starch. If the plasticizer content is too low, the resulting matrix may be brittle and/or the starch spiral structure may be relatively regular, meaning that the small molecules bound in the spirals may be difficult to release during use. Conversely, if the plasticizer content is too high, the resulting matrix may be sticky and difficult to handle and/or the matrix may be irregular, meaning that the bound small molecules may be released too easily during use. Furthermore, if the plasticizer content is too high, the material may absorb water (because plasticizers are hygroscopic), resulting in a material that does not produce a suitable consumer experience during use.

Furthermore, the plasticizer content identified herein provides flexibility to the aerosol generating material, allowing sheets of the material to be wound onto bobbins, which is useful in the manufacture of aerosol product articles.

In some cases, the plasticizer may be an aerosol generating agent. Preferably, the plasticizer comprises one or more compounds selected from erythritol, sorbitol, glycerol, glycols such as propylene glycol, monohydric alcohols, high boiling point hydrocarbons, lactic acid, diacetin, triacetin, triethylene glycol diacetate, triethyl citrate, ethyl myristate, isopropyl myristate, methyl stearate, dimethyl dodecane dioate, and dimethyl tetradecane dioate. Preferably, the plasticizer may comprise one or more of erythritol, propylene glycol, glycerol, triacetin, sorbitol, and xylitol. In some cases, the aerosol generating agent comprises, consists essentially of, or consists of glycerol.

The aerosol-generating material may in some cases be a hydrogel and contain less than about 20 wt%, 15 wt%, 12 wt%, or 10 wt% water, calculated on a wet weight basis (WWB). In some cases, the material may contain at least about 1 wt%, 2 wt%, or 5 wt% water (WWB). In some cases, the amorphous solid contains about 1 wt% to about 15 wt%, or about 5 wt% to about 15 wt% water, calculated on a wet weight basis. Preferably, the water content of the amorphous solid may be about 5 wt%, 7 wt%, or 9 wt% to about 15 wt%, 13 wt%, or 11 wt% (WWB), most preferably about 10 wt%. This water level ensures that the material is relatively resistant to microbial degradation (e.g., mold growth).

The aerosol-generating material may further comprise a flavor or fragrance component derived from a plant. In some cases, this may be a powder component derived from a plant and may have a particle size of less than about 250 μm, preferably less than about 200 μm or 150 μm (i.e., the powder is sieved and passes through a sieve of that size). In some cases, the powder may have an average particle diameter of less than about 250 μm, preferably less than about 200 μm or 150 μm. The inventors have found that if the powder is incorporated into a matrix structure, it is desirable to have a certain particle size, as at larger particle sizes the starch matrix collapses and any attached small molecules are released too easily during use.

The amount of powdered component may preferably be from about 40% to about 300% by weight of the starch, more preferably from about 50% to about 200% or 100% by weight of the starch.

In some cases, the amorphous solid includes an active agent. For example, in some cases, the amorphous solid includes tobacco material and/or nicotine. For example, the amorphous solid may further include powdered tobacco (having a particle size (or average diameter) as discussed above) and/or nicotine and/or a tobacco extract. In such cases, the nicotine and/or tobacco aroma/flavor components of the extract may be bound to the starch. In some cases, the amorphous solid may include from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 80 wt%, 70 wt%, 50 wt%, 45 wt%, or 40 wt% (calculated on a dry weight basis) of the active agent. In some cases, the amorphous solid may comprise from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 80 wt%, 70 wt%, 60 wt%, 50 wt%, 45 wt%, or 40 wt% (calculated on a dry weight basis) of tobacco material and/or nicotine.

In some cases, the amorphous solid includes an active material such as tobacco extract. In some cases, the amorphous solid may include 5-60 wt% tobacco extract (calculated on a dry weight basis). In some cases, the amorphous solid may include about 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 55 wt%, 50 wt%, 45 wt%, or 40 wt% tobacco extract (calculated on a dry weight basis). For example, the amorphous solid may include 5-60 wt%, 10-55 wt%, or 25-55 wt% tobacco extract. The tobacco extract may contain nicotine in a concentration such that the amorphous solid includes 1 wt%, 1.5 wt%, 2 wt%, or 2.5 wt% to about 6 wt%, 5 wt%, 4.5 wt%, or 4 wt% nicotine (calculated on a dry weight basis). In some cases, there may be no nicotine present in the amorphous solid other than that obtained from the tobacco extract.

When the amorphous solid comprises a tobacco extract, the tobacco extract may be an aqueous extract obtained by extraction with water. In some cases, the tobacco extract may be in a plasticizer as a solvent (i.e., obtained by extraction using a plasticizer). The tobacco extract may be an extract from any suitable tobacco, such as a single grade or blend, cut rag or whole leaf, including Virginia and/or Burley and/or Oriental. The tobacco extract may also be an extract from "fine" or dust tobacco particles, expanded tobacco, stems, expanded stems, and other processed stem materials such as cut and rolled stems. The extract may be obtained from ground tobacco material or reconstituted tobacco material.

In some cases, the aerosol-forming material may include a flavoring. In some cases, the flavoring (if present) comprises, consists essentially of, or consists of menthol. Suitably, the amorphous solid may include up to about 60 wt%, 50 wt%, 40 wt%, 30 wt%, 20 wt%, 10 wt%, or 5 wt% flavoring. In some cases, the amorphous solid may include at least about 0.5 wt%, 1 wt%, 2 wt%, 5 wt%, 10 wt%, 20 wt%, or 30 wt% flavoring (all calculated on a dry weight basis). For example, the amorphous solid may include 0.1-60 wt%, 1-60 wt%, 5-60 wt%, 10-60 wt%, 20-50 wt%, or 30-40 wt% flavoring. In some cases, the flavoring, if present, comprises, consists essentially of, or consists of menthol. In some cases, the amorphous solid is flavorless.

In some embodiments, the amorphous solid contains less than 60 wt% of filler, e.g., 1 wt% to 60 wt%, or 5 wt% to 50 wt%, or 5 wt% to 30 wt%, or 10 wt% to 20 wt%.

In other embodiments, the amorphous solid contains less than 20 wt%, preferably less than 10 wt%, or less than 5 wt% filler. In some cases, the amorphous solid contains less than 1 wt% filler, and in some cases, no filler. In some embodiments, the amorphous solid does not contain tobacco fiber. In certain embodiments, the amorphous solid does not contain fibrous material.

When present, the filler may include one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents, such as molecular sieves. The filler may include one or more organic filler materials, such as wood pulp, cellulose and cellulose derivatives. In certain cases, the amorphous solid does not include calcium carbonate, such as chalk.

In certain embodiments that include a filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material, such as wood pulp, hemp fiber, cellulose, or a cellulose derivative. Without wishing to be bound by theory, it is believed that the inclusion of a fibrous filler in the amorphous solid can increase the tensile strength of the material. This can be particularly advantageous in instances where the amorphous solid is provided as a sheet, e.g., where the amorphous solid sheet surrounds a rod of aerosolizable material.

In some cases, the aerosol-forming material may consist essentially of or consist of starch, plasticizer, water, and optionally a botanical-derived flavor or aroma ingredient, and optionally a flavoring. In some cases, the aerosol-forming material may consist essentially of or consist of potato starch, glycerol, tobacco material, and water.

In some cases, the aerosol-generating substrate may further include a carrier on which the solid aerosol-generating material is disposed. This carrier may facilitate manufacture and/or handling, for example, by (a) providing a surface onto which the slurry can be cast (and which does not have to be separated afterwards), (b) providing a non-stick surface for the aerosol-generating substrate that facilitates handling, and (c) providing some rigidity to the substrate.

In some cases, the carrier may be formed from a material selected from metal foil, paper, carbon paper, greaseproof paper, ceramics, carbon allotropes such as graphite and graphene, plastic, cardboard, wood, or combinations thereof. In some cases, the carrier may include or consist of tobacco material, such as a sheet of reconstituted tobacco. In some cases, the carrier may be formed from a material selected from metal foil, paper, cardboard, wood, or combinations thereof. In some cases, the carrier itself is a laminated structure comprising layers of materials selected from the aforementioned list. In some cases, the carrier can function as a flavor carrier. For example, the carrier may be impregnated with flavorings or tobacco extracts.

In some cases, the carrier may be substantially or completely impermeable to gases and/or aerosols. This prevents the aerosol or gas from passing through the carrier during use, thereby controlling the flow and ensuring that the aerosol or gas is delivered to the user. This may also be used to prevent condensation or other deposition of the gas/aerosol during use, for example on the surface of a heater provided in the aerosol generation assembly. Thus, in some cases, consumption efficiency and hygiene may be improved.

In some cases, the carrier of the aerosol product may comprise or consist of a porous layer in contact with the starch matrix. For example, the porous layer may be a paper layer. In some particular cases, the starch layer is placed in direct contact with the porous layer, with the porous layer abutting the starch and forming a strong bond. The starch matrix is formed by drying a gel, and without being limited by theory, it is believed that the gel-forming slurry partially impregnates the porous layer (e.g., paper) so that when the gel hardens and forms crosslinks, the porous layer partially bonds to the gel. This results in a strong bond between the gel and the porous layer (and between the dried gel and the porous layer).

Furthermore, surface roughness can contribute to the strength of the bond between the aerosol generating material and the carrier. The inventors have found that the roughness of the paper (of the surface that abuts the carrier) may be preferably in the range of 50-1000 Bekk seconds, preferably in the range of 50-150 Bekk seconds, preferably 100 Bekk seconds (measured over the pressure interval of 50.66-48.00 kPa). (The Beck smoothness tester is an instrument used to measure the smoothness of paper surfaces, in which air at a specific pressure is inserted between a smooth glass surface and a paper sample, and the time (in seconds) it takes for a fixed volume of air to penetrate between the surfaces is the "Beck smoothness").

Conversely, the surface of the carrier that does not face the aerosol-generating material may be placed in contact with the heater, with a smoother surface providing more efficient heat transfer. Thus, in some cases, the carrier is positioned to have a rougher side that abuts the aerosol-generating material and a smoother side that does not face the aerosol-generating material.

In one particular case, the carrier may be a paper-backed foil, with the paper layer abutting the aerosol generating material and providing the properties discussed in the previous paragraphs. The foil backing is substantially impermeable, providing control of the aerosol flow path. The metal foil backing can also help transfer heat to the aerosol generating material.

In other cases, the foil layer of a paper-backed foil abuts the amorphous solid. The foil is substantially impermeable, thereby preventing absorption of water provided in the amorphous solid into the paper, which could weaken the structural integrity of the paper.

In some cases, the carrier is formed of or comprises a metal foil, such as aluminum foil. The metal carrier may allow for better transfer of thermal energy to the amorphous solid. Additionally or alternatively, the metal foil may function 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 these embodiments, the metal foil layer may have a thickness of less than 20 μm, for example, from about 1 μm to about 10 μm, preferably about 5 μm.

In some cases, the carrier may be magnetic. This functionality can be used to secure the carrier to the assembly during use. In some cases, the aerosol-generating substrate may include one or more magnets that can be used to secure the substrate to an induction heater during use.

In some cases, the aerosol-generating substrate may include a heating means, such as a resistive or inductive heating element, embedded in the aerosol-generating material.

In some cases, the amorphous solid may have a thickness of about 0.015 mm to about 1.0 mm. Suitably, the thickness may range from about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm. The inventors have found that a material having a thickness of 0.2 mm is particularly suitable. The inventors have established that if the aerosol generating material is too thick, heating efficiency is compromised. This adversely affects power consumption during use. Conversely, if the material is too thin, it is difficult to manufacture and handle, and very thin materials are more difficult to cast, are prone to breakage, and may compromise aerosol formation during use. In some cases, the thicknesses specified herein are the average thickness of the material. In some cases, the layer thickness may vary by 25%, 20%, 15%, 10%, 5%, or 1% or less.

The aerosol-generating material may be formed as a sheet, which may be incorporated into an article in sheet form. In some cases, the aerosol-generating material may be included as a flat sheet, as a pleated or gathered sheet, as a corrugated sheet, or as a rolled sheet (i.e., in the form of a tube). In some cases, the sheet may be used as a packaging material that at least partially surrounds other elements of the aerosol product article, such as another aerosolizable material (e.g., tobacco). In some other cases, the aerosol-generating material may be formed as a sheet and then shredded and incorporated into an article. In some cases, the shredded sheet may be mixed with cut rag tobacco and incorporated into an article.

The aerosol-generating material comprising the amorphous solid may have any suitable areal density, such ^{as from} 30 g/m to 120 g/m. In some embodiments, the aerosol-generating material may have an areal density of about 30 to 70 g/ ^m , or about 40 to 60 g/ ^m . In some embodiments, the amorphous solid may have an areal density of about 80 to 120 g/ ^m , or about 70 to 110 g/ ^m , or especially about 90 to 110 g/ ^m . Such areal densities may be particularly suitable when the aerosol-generating material is included in the aerosol product article/assembly in sheet form or as shredded sheets (described further herein below). For example, an aerosol-generating material having a mass per unit area of 80 to 120 g/ ^m has a density comparable to cut rag tobacco, such that mixtures of these components do not readily separate.

In some examples, the amorphous solid in sheet form may have a tensile strength of approximately 200 N/m to approximately 900 N/m. In some examples, such as when the amorphous solid does not include a filler, the amorphous solid may have a tensile strength of 200 N/m to 400 N/m, or 200 N/m to 300 N/m, or about 250 N/m. Such tensile strength may be particularly suitable for embodiments in which the aerosol generating material is formed as a sheet and then chopped and incorporated into an aerosol product article. In some examples, such as when the amorphous solid includes a filler, the amorphous solid may have a tensile strength of 600 N/m to 900 N/m, or 700 N/m to 900 N/m, or approximately 800 N/m. Such tensile strength may be particularly suitable for embodiments in which the aerosol generating material is included in an aerosol product article/assembly as a rolled sheet, preferably in the form of a tube.

In some cases, the article may further include a filter and/or a cooling element. In some cases, the aerosol product may be surrounded by a packaging material, such as paper.

A second aspect of the invention provides an aerosol generating assembly comprising an aerosol product article according to the first aspect of the invention and a heater configured to heat but not combust the aerosol generating material.

The heater may be a thin-film electrical resistance heater in some cases. In other cases, the heater may comprise a heater such as an induction heater. The heater may be a combustion-type heat source or may be a chemical heat source that undergoes an exothermic reaction to generate heat during use. The aerosol generation assembly may comprise multiple heaters. The heater(s) may be powered by a battery.

In some cases, the heater, in use, can heat the aerosolizable material to 120°C to 350°C without burning the aerosolizable material. In some cases, the heater, in use, can heat the aerosolizable material to 140°C to 250°C without burning the aerosolizable material. In some cases, in use, substantially all of the amorphous solid is less than about 4 mm, 3 mm, 2 mm, or 1 mm from the heater. In some cases, the solid is located about 0.010 mm to 2.0 mm, preferably about 0.02 mm to 1.0 mm, preferably 0.1 mm to 0.5 mm from the heater. These minimum distances may in some cases reflect the thickness of a carrier supporting the amorphous solid. In some cases, the surface of the amorphous solid may directly abut the heater.

In some cases, the heater may be embedded in the aerosol-generating substrate. In some such cases, the heater may be an electrical resistance heater (with exposed contacts for connection to an electrical circuit). In other such cases, the heater may be a susceptor embedded in the aerosol-generating gas that is heated by induction.

The aerosol generation assembly may further comprise a cooling element and/or a filter. The cooling element, if present, may act or function to cool the gas or aerosol components. In some cases, the cooling element may act to cool the gas components such that they condense to form the aerosol. The cooling element may also act to move very hot parts of the device away from the user. The filter, if present, may comprise any suitable filter known in the art, such as a cellulose acetate plug.

In some cases, the aerosol generation assembly may be a non-combustion heated device. A non-combustion heated device is disclosed in WO 2015/062983 A2, which is incorporated by reference in its entirety. In some cases, the aerosol generation assembly may be an e-cigarette hybrid device. An e-cigarette hybrid device is disclosed in WO 2016/135331 A1, which is incorporated by reference in its entirety.

The aerosol product article or assembly may further comprise ventilation openings. The ventilation openings may be provided in the sidewalls of the article. In some cases, the ventilation openings may be provided in the filter and/or cooling element. These openings may allow cool air to be drawn into the article during use, where it can mix with the heated volatile components, thereby cooling the aerosol.

Ventilation promotes the production of visible heated volatiles from the article when the article is heated in use. The heated volatiles are made visible by cooling the heated volatiles such that supersaturation of the heated volatiles occurs. The heated volatiles then undergo droplet formation, otherwise known as nucleation, and finally the size of the aerosol particles of the heated volatiles increases due to further condensation of the heated volatiles and by coalescence of the newly formed droplets from the heated volatiles.

In some cases, the ratio of cool air to the sum of heated volatiles and cool air, known as the ventilation ratio, is at least 15%. A ventilation ratio of 15% allows the heated volatiles to be made visible by the methods described above. The visibility of the heated volatiles allows the user to identify that volatiles are being produced, enhancing the user's sensory experience of the smoking experience.

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

The assembly may include an integrated aerosol production article and a heater. For example, the integrated heater may be a combustion-type or chemical heat source that, in use, heats the aerosol-generating substrate without combusting it. Alternatively, the assembly may include a heater device into which the article is inserted in use, the heater being configured to heat but not combust the aerosol-generating substrate.

With reference to Figures 1 and 2, a partially cut-away cross-sectional view and a perspective view of an example aerosol product article 101 are shown. The article 101 is adapted for use with a device having a power source and a heater. This embodiment of the article 101 is particularly suited for use with the device 51 shown in Figures 5-7, described below. In use, the article 101 can be removably inserted into the device at the insertion point 20 of the device 51 shown in Figure 5.

The example article 101 is in the form of a substantially cylindrical rod comprising a body 103 of aerosol-generating material and a filter assembly 105 in the form of a rod. The aerosol-generating material comprises a starch matrix material as described herein. In some embodiments, the aerosol-generating material may be included in sheet form. In some embodiments, the aerosol-generating material may be included in chopped sheet form. In some embodiments, the aerosol-generating material as described herein may be incorporated in sheet form and chopped form.

The filter assembly 105 comprises three segments: a cooling segment 107, a filter segment 109, and an oral end segment 111. The article 101 has a first end 113, also known as the oral end or distal end, and a second end 115, also known as the distal end. The aerosol-generating material body 103 is located toward the distal end 115 of the article 101. In one example, the cooling segment 107 is located adjacent to the aerosol-generating material body 103 between the aerosol-generating material body 103 and the filter segment 109 such that the cooling segment 107 is in an abutting relationship with the aerosol-generating material body 103 and the filter segment 109. In another example, there may be a separation between the aerosol-generating material body 103 and the cooling segment 107 and between the aerosol-generating material body 103 and the filter segment 109. The filter segment 109 is located between the cooling segment 107 and the oral end segment 111. The oral end segment 111 is located toward the proximal end 113 of the article 101 and is adjacent to the filter segment 109. In one example, the filter segment 109 is in an abutting relationship with the oral end segment 111. In one embodiment, the overall length of the filter assembly 105 is between 37 mm and 45 mm, and more preferably, the overall length of the filter assembly 105 is 41 mm.

In one example, the rod of aerosol-generating material 103 is 34 mm to 50 mm long, preferably 38 mm to 46 mm long, preferably 42 mm long.

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

The axial end of the body of aerosol-generating material 103 is visible at the distal end 115 of the article 101. However, in other embodiments, the distal end 115 of the article 101 may include an end member (not shown) that covers the axial end of the body of aerosol-generating material 103.

The body of aerosol-generating material 103 is joined to the filter assembly 105 by an annular tipping paper (not shown) that is located substantially around the periphery of the filter assembly 105 so as to surround the filter assembly 105 and extends partially along the length of the body of aerosol-generating material 103. In one example, the tipping paper is made from 58 GSM standard tipping base paper. In one example, the tipping paper has a length of 42 mm to 50 mm, preferably 46 mm.

In one example, the cooling segment 107 is an annular tube that is positioned around and defines a gap in the cooling segment. The gap provides a chamber through which the generated heated volatile components flow from the body of aerosol-generating material 103. The cooling segment 107 is hollow to provide a chamber for aerosol accumulation, yet is rigid enough to withstand axial compressive forces and bending moments that may occur during manufacture and use during insertion of the article 101 into the device 51. In one example, the wall thickness of the cooling segment 107 is approximately 0.29 mm.

The cooling segment 107 provides a physical displacement between the aerosol generating material 103 and the filter segment 109. The physical displacement provided by the cooling segment 107 provides a thermal gradient along the length of the cooling segment 107. In one example, the cooling segment 107 is configured to provide a temperature difference of at least 40 degrees Celsius between the heated volatile component entering the first end of the cooling segment 107 and the heated volatile component exiting the second end of the cooling segment 107. In one example, the cooling segment 107 is configured to provide a temperature difference of at least 60 degrees Celsius between the heated volatile component entering the first end of the cooling segment 107 and the heated volatile component exiting the second end of the cooling segment 107. This temperature difference along the length of the cooling element 107 protects the temperature-sensitive filter segment 109 from the high temperature of the aerosol generating material 103 when the aerosol generating material 103 is heated by the device 51. If no physical displacement is provided between the filter segment 109 and the body of aerosol-generating material 103 and the heating element of the device 51, the temperature-sensitive filter segment 109 may become damaged during use and therefore may not effectively perform its required function.

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

The cooling segment 107 is made of paper, meaning that it is constructed of a material that does not produce compounds of concern, e.g., toxic compounds, when adjacent to the heater of the device 51 in use. In one example, the cooling segment 107 is manufactured from a spirally wound paper tube that provides a hollow interior chamber, yet maintains mechanical rigidity. A spirally wound paper tube can meet the stringent dimensional accuracy requirements of high speed manufacturing processes with respect to tube length, outer diameter, roundness, and straightness.

In another example, the cooling segment 107 is a recess made from stiff plug wrap or tipping paper. The stiff plug wrap or tipping paper is manufactured to be sufficiently stiff to withstand axial compressive forces and bending moments that may occur during manufacture and in use during insertion of the article 101 into the device 51.

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

In some embodiments, a capsule (not shown) may be provided in the filter segment 109. The capsule may be located substantially in the center of the filter segment 109, both in the direction of the diameter of the filter segment 109 and in the direction of the length of the filter segment 109. In other cases, the capsule may be off-center in one or more dimensions. In some cases, the capsule, if present, may contain a volatile component such as a flavoring or an aerosol generating agent.

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

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

The presence of filter segment 109 provides an insulating effect by further cooling the heated volatile components exiting cooling segment 107. This additional cooling effect reduces the temperature of the user's lips on contact with the surface of filter segment 109.

In one example, the filter segment 109 is 6 mm to 10 mm long, preferably 8 mm long.

The mouth end segment 111 is an annular tube that is positioned around and defines a cavity within the mouth end segment 111. The cavity provides a chamber for heated volatile components flowing from the filter segment 109. The mouth end segment 111 is hollow to provide a chamber for aerosol accumulation, yet is rigid enough to withstand axial compressive forces and bending moments that may occur during manufacture and use during insertion of the article into the device 51. In one example, the wall thickness of the mouth end segment 111 is approximately 0.29 mm. In one example, the length of the mouth end segment 111 is 6 mm to 10 mm, preferably 8 mm.

The mouth end segment 111 may be manufactured from a spirally wound paper tube that provides a hollow interior chamber but still maintains significant mechanical rigidity. A spirally wound paper tube can meet the stringent dimensional accuracy requirements of high speed manufacturing processes with respect to tube length, outside diameter, roundness and straightness.

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

It is recognized that in one example, the mouth end segment 111 and the cooling segment 107 may be formed from a single tube, with the filter segment 109 located within the tube to separate the mouth end segment 111 and the cooling segment 107.

Referring now to Figures 3 and 4, a partially cut-away cross-sectional view and a perspective view of an example of article 301 are shown. The reference numbers shown in Figures 3 and 4 correspond to the reference numbers shown in Figures 1 and 2, but are increased by 200.

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

In one example, there are 1-4 rows of vent holes to provide ventilation to the article 301. Each row of vent holes may have 12-36 vent holes 317. The vent holes 317 may be, for example, 100-500 μm in diameter. In one example, the axial spacing between the rows of vent holes 317 is 0.25 mm-0.75 mm, preferably 0.5 mm.

In one example, the vent holes 317 are of uniform size. In another example, the vent holes 317 vary in size. The vent holes can be created using any suitable technique, such as one or more of laser techniques, mechanical drilling of the cooling segment 307, or pre-drilling of the cooling segment 307 before it is formed in the article 301. The vent holes 317 are positioned to effectively cool the article 301.

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

By providing a row of vent holes 17-20 mm from the proximal end 313 of the article 301, the vent holes 317 can be located on the outside of the device 51 when the article 301 is fully inserted into the device 51, as can be seen in Figures 6 and 7. By having the vent holes located on the outside of the device, unheated air can enter the article 301 from outside the device 51 through the vent holes to help cool the article 301.

The length of the cooling segment 307 is such that when the item 301 is fully inserted into the device 51, the cooling segment 307 is partially inserted into the device 51. The length of the cooling segment 307 provides a first function of providing a physical gap between the heater arrangement and the heat-sensitive filter arrangement 309 of the device 51, and a second function of allowing the vent 317 to be located within the cooling segment while also being located outside the device 51 when the item 301 is fully inserted into the device 51. As can be seen from Figures 6 and 7, the majority of the cooling element 307 is located within the device 51. However, a portion of the cooling element 307 extends outside the device 51. The vent 317 is located in this portion of the cooling element 307 that extends outside the device 51.

Referring now to Figures 5-7 in more detail, an example of a device 51 is shown that is configured to heat an aerosol-generating material to volatilize at least one component of said aerosol-generating material, typically to form an inhalable aerosol. Device 51 is a heating device that releases compounds by heating but not combusting the aerosol-generating material.

The first end 53 may be referred to herein as the oral or proximal end 53 of the device 51, and the second end 55 may be referred to herein as the distal end 55 of the device 51. The device 51 has an on/off button 57 that allows the entire device 51 to be activated and deactivated as desired by the user.

The device 51 includes a housing 59 for mounting and protecting various internal components of the device 51. In the example shown, the housing 59 includes a unitary sleeve 11 that surrounds the outer edge of the device 51, the sleeve 11 being capped with a top panel 17 that generally defines the "top" of the device 51, and a bottom panel 19 that generally defines the "bottom" of the device 51. In another example, the housing includes a front panel, a rear panel, and a pair of opposing side panels in addition to the top panel 17 and bottom panel 19.

The top panel 17 and/or bottom panel 19 may be removably secured to the unitary sleeve 11 to allow easy access to the interior of the device 51, or may be "permanently" secured to the unitary sleeve 11, for example to prevent a user from accessing the interior of the device 51. In one example, the panels 17 and 19 are made of a plastic material including, for example, glass-filled nylon formed by injection molding, and the unitary sleeve 11 is made of aluminum, although other materials and manufacturing processes may be used.

The top panel 17 of the device 51 has an opening 20 at the mouth end 53 of the device 51, and during use, a user can insert and remove an article 101, 301 containing an aerosol-generating material into and from the device 51 through the opening 20.

The heater arrangement 23, the control circuitry 25, and the power supply 27 are located or fixed in the housing 59. In this example, the heater arrangement 23, the control circuitry 25, and the power supply 27 are laterally adjacent (i.e., adjacent when viewed from one end), and the control circuitry 25 is generally located between the heater arrangement 23 and the power supply 27, although other arrangements are possible.

The control circuitry 25 may include a controller, such as a microprocessor arrangement, configured and arranged to control the heating of the aerosol generating material within the article 101, 301, as discussed further below.

The power source 27 may be, for example, a battery, which may be a rechargeable or non-rechargeable battery. Examples of suitable batteries include, for example, lithium ion batteries, nickel batteries (e.g., nickel cadmium batteries), alkaline batteries, and/or the like. The battery 27 is electrically connected to the heater arrangement 23 and provides power under the control of the control circuit 25 when needed to heat the aerosol-forming material in the article (as discussed, to volatilize the aerosol-forming material without burning it).

An advantage of having the power source 27 located laterally adjacent to the heater structure 23 is that a physically larger power source 25 can be used without making the overall device 51 excessively long. As will be appreciated, a physically larger power source 25 generally has a higher capacity (i.e., total electrical energy that can be delivered, often measured in ampere-hours or the like) and therefore can provide a longer battery life for the device 51.

In one example, the heater configuration 23 is generally in the form of a hollow cylindrical tube having a hollow internal heating chamber 29 into which the article 101, 301 containing the aerosol-generating material is inserted for heating during use. Various configurations of the heater configuration 23 are possible. For example, the heater configuration 23 may comprise a single heating element or may be formed of multiple heating elements aligned along the longitudinal axis of the heater configuration 23. The or each heating element may be annular or tubular, or may be at least partially annular or at least partially tubular along 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 ceramics and aluminum nitride ceramics and silicon nitride ceramics, which may be layered and sintered. Other heating configurations are possible, including, for example, induction heating, infrared heating elements that heat by radiating infrared radiation, and resistive heating elements formed, for example, by resistive electrical windings.

In one particular 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 such that substantially the entire aerosol-generating material body 103, 303 of the article 101, 301 is inserted into the heater arrangement 23 when the article 101, 301 is inserted into the device 51.

The, or each, heating element may be positioned to heat selected zones of the aerosol-generating material independently, for example, sequentially (over time, as discussed above) or together (simultaneously), as desired.

The heater component 23 in this example is surrounded by insulation 31 along at least a portion of its length. The insulation 31 helps to reduce heat passing from the heater component 23 to the exterior of the device 51. This generally reduces heat loss and therefore helps to keep the power requirements of the heater component 23 low. The insulation 31 also helps to keep the exterior of the device 51 cool during operation of the heater component 23. In one example, the insulation 31 may be a double-walled sleeve that provides a low pressure area between the two walls of the sleeve. That is, the insulation 31 may be, for example, a "vacuum" tube, i.e., a tube that is at least partially evacuated to minimize heat transfer by conduction and/or convection. Other configurations for the insulation 31 are possible, including the use of insulation in addition to or instead of the double-walled sleeve, including, for example, a suitable foam-type material.

The housing 59 may further include various internal support structures 37 for supporting all internal components as well as the heating arrangement 23.

The device 51 further comprises a collar 33 extending around the opening 20 and projecting from the opening 20 into the interior of the housing 59, and a generally tubular chamber 35 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 exterior surface of the chamber 35, each fin being arranged to surround the exterior surface of the chamber 35. When the article 101, 301 is inserted into the device 51 over at least a portion of the length of the hollow chamber 35, there is a gap 36 between the hollow chamber 35 and the article 101, 301. The gap 36 surrounds the entire circumference of the article 101, 301 over at least a portion of the cooling segment 307.

The collar 33 includes a plurality of ridges 60 arranged around the periphery of the opening 20, which protrude into the opening 20. The ridges 60 occupy space within the opening 20 such that the opening distance of the opening 20 at the location of the ridges 60 is less than the opening distance of the opening 20 without the ridges 60. The ridges 60 are configured to engage with the article 101, 301 inserted into the device to help secure it within the device 51. The open space (not shown) defined by adjacent pairs of the ridges 60 and the article 101, 301 forms ventilation paths around the periphery of the article 101, 301. These ventilation paths allow hot steam escaping from the article 101, 301 to exit the device 51 and allow cooling air to flow around the article 101, 301 in the gap 36 to the device 51.

In operation, the article 101, 301 is removably inserted into the insertion point 20 of the device 51, as shown in Figures 5-7. With particular reference to Figure 6, in one example, the body of aerosol-generating material 103, 303 located toward the distal end 115, 315 of the article 101, 301 is completely contained within the heater arrangement 23 of the device 51. The proximal end 113, 313 of the article 101, 301 extends from the device 51 and acts as a mouthpiece assembly for the user.

In operation, the heater arrangement 23 heats the article 101, 301 to volatilize at least one component of the aerosol-generating material from the aerosol-generating material body 103, 303.

The primary flow path for the heated volatile components from the aerosol-generating body 103, 303 is axially through the article 101, 301, through the inner chamber of the cooling segment 107, 307, through the filter segment 109, 309, and through the mouth end segment 111, 313 to the user. In one example, the heated volatile components generated from the aerosol-generating body are at a temperature between 60° C. and 250° C., which may be above the inhalation temperature acceptable to the user. The heated volatile components are cooled as they travel through the cooling segment 107, 307, and some of the volatile components condense on the inner surface of the cooling segment 107, 307.

In the example of article 301 shown in Figures 3 and 4, cool air can enter cooling segment 307 through vents 317 formed in cooling segment 307. The cool air mixes with the heated volatile components to further cool the heated volatile components.

A third aspect of the present invention is a method for producing a composition comprising the steps of:
A plasticizer in an amount of about 5% to 70% by weight of the starch;
The present invention provides a starch matrix material containing a plant-derived flavor or fragrance component.

The features described herein in relation to the "aerosol-generating material" are expressly disclosed herein in combination with the third aspect of the invention.

Preferably, the plant-derived flavour or aroma component comprises a tobacco material, such as a tobacco extract.

Preferably, the plant-derived flavor or fragrance ingredient may be a powdered ingredient added in an amount of 40% to 300% by weight of the starch.

The present invention also provides a method of making an aerosol product according to the first aspect, comprising the steps of:
(i) mixing the components of an aerosol-generating material into a slurry, heating and stirring the slurry to gel, casting the gel, and drying by heating to form an aerosol-generating material;
(ii) incorporating the aerosol-forming material into an aerosol product.

In some cases, the heating and stirring step may include heating to approximately 70-100°C, preferably 85°C, for up to about 20 minutes. The drying step may include heating to approximately 30-70°C, preferably 50°C, for 1-5 hours, preferably approximately 3 hours.

The method may include an additional step including shredding the aerosol-generating material before it is incorporated into the aerosol product.

The present invention also provides
Starch,
A plasticizer in an amount of about 5% to 70% by weight of the starch;
A fragrance or fragrance ingredient derived from a plant;
and water.

Preferably, the weight ratio of water to the total weight of other ingredients is about 10:1 to 20:1.

In some examples, the slurry has a viscosity of about 10 to about 20 Pa·s at 46.5°C, for example, a viscosity of about 14 to about 16 Pa·s at 46.5°C.

The present invention also provides
Starch,
A plasticizer in an amount of about 5% to 70% by weight of the starch;
a powdered tobacco material having an average particle diameter of less than about 250 μm in an amount of about 40% to 300% by weight of the starch;
and water, wherein the weight ratio of water to the total weight of other ingredients is about 10:1 to 20:1.

The present invention also provides
Starch,
A plasticizer in an amount of about 5% to 70% by weight of the starch;
and an aqueous tobacco extract, the weight ratio of water to the total weight of other ingredients being about 10:1 to 20:1.

A further aspect of the present invention is
(iii) a wrapping material for a smoking article or an aerosol product comprising a starch matrix and a plasticizer, the amount of plasticizer being about 5% to 30% by weight of the starch; and (iv) a filter for a smoking article or an aerosol product comprising a starch matrix and a plasticizer, the amount of plasticizer being about 5% to 15% by weight of the starch.

The inventors have established the use of these starch matrix materials as filters and wrappers, in addition to their use as aerosol generating materials.

The present invention also provides an article comprising the above-mentioned wrapping material and/or filter.

Example 1
Starch matrix films were prepared as follows.

1000 mg potato starch, 300 mg glycerol and 20 mL water were added to a 50 mL beaker. The slurry was stirred using a stir bar and the mixture was heated to 85°C for 10 minutes under vigorous stirring. Thickening (or gelling) of the mixture was observed.

The gel was cast onto a PTFE sheet (the gel is very polar and therefore adheres strongly to glass or metal). The material was dried at 50°C for 2 hours to produce a 4 mm thick film.

Example 2
In another example, 500-2000 mg of tobacco powder (particle size 200 μm) was added to the mixture before mixing, and the method of Example 1 was used to prepare a starch matrix film.

Example 3
In another example, a starch matrix film was made using the method of Example 1, except that the water was replaced with 20 mL of aqueous tobacco extract (obtained by extraction of Virginia ground tobacco with deionized water) and 450 mg of glycerol was used (instead of 300 mg).

Testing Each example material is heated without combustion in a simulated smoking regime (heat to 250° C. and puffed for 2 seconds every 30 seconds under an airflow of 1.65 L/min).

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

In some embodiments, the active substance includes nicotine.

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

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

Cannabinoids are a class of natural or synthetic compounds that act on cellular cannabinoid receptors (i.e., CB1 and CB2) to inhibit neurotransmitter release in the brain. Cannabinoids may be naturally occurring from plants such as cannabis (phytocannabinoids), from animals (endocannabinoids), or may be artificially produced (synthetic cannabinoids). Cannabis species express at least 85 different phytocannabinoids, divided into subclasses including cannabigerol, cannabichromene, cannabidiol, tetrahydrocannabinol, cannabinol and cannabinodiol, as well as other cannabinoids. Cannabinoids found in Cannabis include, without limitation, cannabigerol (CBG), cannabichromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol (CBN), cannabinodiol (CBDL), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabinerolic acid, cannabidiolic acid (CBDA), cannabinol propyl variant (CBNV), cannabidiol (CBO), tetrahydrocannabimolic acid (TCA), cannabinol propyl variant (CBNV), cannabidiol (CBO), cannabinol propyl variant (CBN ... acid (THCA) and tetrahydrocannabivaric acid (THCV A).

As described herein, the active material may include or be derived from one or more botanical materials or components, derivatives, or extracts thereof. As used herein, the term "botanical material" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, skins, shells, and the like. Alternatively, the material may include synthetically derived active compounds naturally occurring in a plant. The material may be in the form of a liquid, gas, solid, powder, dust, ground particles, granules, pellets, shreds, strips, sheets, and the like. Examples of botanical substances include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, bay, licorice (licorice), matcha, yerba mate, orange peel, papaya, rose, sage, tea such as green tea or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemongrass, lemon juice, lemon juice powder, lemon juice syrup ... The preferred active ingredients include caramel, laurel, laurel bark, mint, juniper, elderflower, vanilla, wintergreen, shiso, turmeric, sandalwood, coriander leaf, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiane, marjoram, olive, lemon balm, lemon basil, chives, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. Mints include the following mint varieties: Mentha arvensis, Mentha c.v., Mentha niliaca, peppermint, Mentha piperita, cologne mint, Mentha piperita c.v., Mentha piperita c.v., Mentha spicata crispa, Mentha cordifolia, Mentha longifolia, and pineapple mint. variegata), Mentha pulegium, Mentha spicata c.v., and Mentha suaveolens.

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

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

As used herein, the terms "flavor" and "flavoring agent" refer to materials that can be used to create a desired taste, aroma, or other bodily sensation in adult consumer products, where permitted by local regulations. These include naturally occurring flavor materials, botanical substances, extracts of botanical substances, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice (licorice), hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese peppermint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, etc. , papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberries, mulberries, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, mint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel quid, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-yi Orchid, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, bay, yerba mate, orange peel, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, turmeric, coriander leaves, myrtle, black currant, valerian, piment o), mace, damian, marjoram, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, limonene, thymol, camphor), flavor enhancers, bitter receptor site blockers, sensory receptor site activators or stimulants, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals or breath fresheners. They may be imitation, synthetic or natural ingredients, or blends thereof. They may be in any suitable form, for example liquids such as oils, solids such as powders, or gases.

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

In some embodiments, the flavoring includes menthol, peppermint, and/or mint.

In some embodiments, the flavoring includes cucumber, blueberry, citrus, and/or red berry flavor ingredients.

In some embodiments, the fragrance comprises eugenol.

In some embodiments, the flavoring comprises flavor components extracted from tobacco.

In some embodiments, the flavoring comprises flavoring ingredients extracted from cannabis.

In some embodiments, the flavoring may include sensates intended to achieve a physical sensation that is typically chemically induced or perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of the olfactory or gustatory nerves. Suitable heat effect agents may be, but are not limited to, vanillyl ethyl ether, and suitable cooling agents may be, but are not limited to, eucalyptol, WS-3.

As used herein, the term "aerosol generating agent" refers to an agent that facilitates the generation of an aerosol. An aerosol generating agent can facilitate the generation of an aerosol by facilitating the initial vaporization and/or condensation of a gas into an inhalable solid and/or liquid aerosol.

As used herein, the term "tobacco material" refers to any material that contains tobacco or its derivatives. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. Tobacco material may include one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, reconstituted tobacco, and/or tobacco extract.

The tobacco used to produce the tobacco material may be any suitable tobacco, such as single grades or blends, cut rag or whole leaf, including Virginia and/or Burley and/or Oriental. It may also be "fine" or dust tobacco particles, 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 fiber and may be formed by casting, a Fourdrinier type technique with back addition of tobacco extract, or by extrusion.

All weight percentages (written as wt%) described herein are calculated on a dry weight basis unless expressly stated otherwise. All weight ratios are also calculated on a dry weight basis. Weights given on a dry weight basis refer to the totality of the extract or slurry or material other than water, and may include ingredients that are themselves liquid at room temperature and pressure, such as glycerol. Conversely, weight percentages given on a wet weight basis refer to all ingredients, including water.

For the avoidance of doubt, where the term "comprising" is used herein to define an invention or a feature of the invention, embodiments are also disclosed in which the invention or feature may be defined using the term "consisting essentially of" or "consisting of" instead of "comprising." Reference to a material that "comprises" certain features means that those features are included, contained, or retained in the material.

The above-described embodiments are to be understood as illustrative of the present invention. Any feature described in connection with any one of the embodiments may be used alone or in combination with other features described, and may also be used in combination with one or more features of any other of the embodiments, or in any combination with any other of the embodiments. Moreover, equivalents and variations not described above may also be used without departing from the scope of the present invention, which is defined in the appended claims.

Claims (13)

An aerosol product article for use in an aerosol generating assembly, the article comprising an aerosol generating substrate comprising an aerosol generating material, the aerosol generating material being solid and comprising starch and a plasticizer, the amount of plasticizer being between about 5% and 70% by weight of the starch. The aerosol product of claim 1, wherein the amount of plasticizer is about 20% to 50% by weight of the starch. The aerosol product of any one of claims 1 to 2, wherein the aerosol-generating material further comprises a tobacco material. The aerosol product of claim 3, wherein the tobacco material comprises a powdered tobacco material having a particle size of less than about 250 μm. 4. The aerosol product of claim 3 , wherein the tobacco material comprises a tobacco extract. The aerosol product according to any one of claims 1 to 5, wherein the plasticizer is selected from erythritol, sorbitol, glycerol, glycols such as propylene glycol, monohydric alcohols, high boiling point hydrocarbons, lactic acid, diacetin, triacetin, triethylene glycol diacetate, triethyl citrate, ethyl myristate, isopropyl myristate, methyl stearate, dimethyl dodecanedioate and dimethyl tetradecanedioate. The aerosol product of any one of claims 1 to 6, wherein the starch comprises potato starch. The aerosol product article according to any one of claims 1 to 7, wherein the solid aerosol-generating material is formed as a sheet. 9. The aerosol product article of claim 8 , wherein the aerosol-forming material has a mass per unit area of 80 to 120 g/ ^m2 . The aerosol product article according to any one of claims 1 to 9, wherein the aerosol-generating substrate comprises a carrier on which the aerosol-generating material is provided. An aerosol generating assembly comprising an aerosol product according to any one of claims 1 to 10 and a heater configured to heat but not combust the aerosol generating material. A kit comprising an aerosol product article according to any one of claims 1 to 10 and a device configured to contain the article in use, the device including a heater configured to heat but not combust the aerosol-generating material in use. A method of making an aerosol product according to any one of claims 1 to 10, comprising the steps of:
(i) mixing components of an aerosol-generating material to form a slurry, heating and stirring the slurry to gel, casting the gel, and drying by heating to form the aerosol-generating material;
(ii) incorporating the aerosol forming material into the aerosol product;
A method comprising:

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