JP2025500197A - Aerosol-Generating Materials - Google Patents

Abstract

The present invention relates to an aerosol-generating material comprising a blend, the blend comprising at least 20% laminar tobacco, the material being in the form of discrete particles.The present invention also relates to an article for an aerosol delivery system comprising a first aerosol-generating material and a second aerosol-generating material.
[Selection diagram] None

Description

The present disclosure relates to aerosol-forming materials comprising laminar tobacco, methods of making the aerosol-forming materials, and articles for use in non-combustion aerosol delivery systems comprising the aerosol-forming materials.

Additionally, the present disclosure relates to an article for use in an aerosol delivery system, comprising a first aerosol generating material of a first form and a second aerosol generating material of a second form, wherein the first and second aerosol generating materials are made from the same blend.

background

Aerosol delivery systems generate an inhalable aerosol or vapour during use by releasing a compound from an aerosol-generating material. These may be referred to, for example, as non-combustion smoking articles, aerosol generating assemblies or aerosol delivery devices.

overview

According to a first aspect, an aerosol-generating material is provided that includes a blend. The blend includes at least 20% laminar tobacco by weight of the blend, and the aerosol-generating material is in the form of discrete particles.

According to a second aspect, an article for an aerosol delivery system is described that includes a first aerosol generating material in a first form and a second aerosol generating material in a second form. The first and second aerosol generating materials are prepared from the same blend, and the first and second forms are different.

An embodiment of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

FIG. 2 is a longitudinal cross-sectional view of the rod. FIG. 13 is a longitudinal cross-sectional view of a rod having an alternative construction. FIG. 13 is a longitudinal cross-sectional view of a rod having another alternative construction. 1 is a longitudinal cross-sectional view of an article for use in an aerosol delivery system, including a mouth end section. FIG. 2 is a longitudinal cross-sectional view of an article for use in an aerosol delivery system, comprising a mouth end assembly including a spacer section as a cooling section and a mouth end section. FIG. 2 is a longitudinal cross-sectional view of an article for use in an aerosol delivery system, comprising a mouth end assembly including a spacer section as a cooling section and a tubular mouth end section.

Detailed Description

As used herein, the term "delivery system" is intended to encompass systems that deliver at least one substance to a user, including:
Combustion aerosol delivery systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for rolling or homemade cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smoking materials);
Non-combustion aerosol delivery systems that release a compound from an aerosol-generating material without combusting the aerosol-generating material, such as e-cigarettes, tobacco heating products, and hybrid systems that use a combination of aerosol-generating materials to generate an aerosol; and aerosol-free delivery systems that deliver at least one substance, which may or may not contain nicotine, to a user orally, nasally, transdermally, or otherwise without forming an aerosol, including, but not limited to, lozenges, gums, patches, articles containing inhalable powders, and oral tobacco products, including snus or moist snuff.

In accordance with this disclosure, a "non-combustion" aerosol delivery system is one that does not combust or burn the constituent aerosol-generating materials of the aerosol delivery system (or its components) to facilitate delivery of at least one substance to a user.

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

In some embodiments, the non-combustion aerosol delivery system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol generating material is not a requirement.

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

In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates an aerosol using a combination of aerosol-generating materials, one or more of which may be heated. Each aerosol-generating material may be, for example, in solid, liquid, or gel form and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or a non-tobacco product.

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

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

In some embodiments, the non-combustion aerosol delivery system, e.g., the non-combustion aerosol delivery device, may include a power source and a controller. The power source may be, for example, an electrical power source or a heat generating power source. In some embodiments, the heat generating power source includes a carbon substrate that may be energized to distribute electrical power in the form of heat to an aerosol generating material or heat transfer material proximate to the heat generating power source.

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

In some embodiments, consumables for use in non-combustion aerosol delivery devices may include aerosol generating materials, aerosol generating material storage areas, aerosol generating material transfer parts, aerosol generators, aerosol generating areas, housings, wrappers, filters, mouthpieces, and/or aerosol modifiers.

In some embodiments, the substance to be delivered includes an active agent.

As used herein, an active substance may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, functional foods, nootropics, psychoactive agents. The active substance may be naturally occurring or synthetically derived. The 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. The active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or another botanical substance.

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

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

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, fiber, stems, roots, seeds, flowers, fruits, pollen, husks, pods, and the like. Alternatively, the material may include synthetically derived active compounds naturally occurring in the botanical material. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, fragments, strips, sheets, and the like. Examples of botanical substances include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, laurel, 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, and lavender. In some embodiments, the active ingredient is an herb, such as lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, allspice, mace, damiene, 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. The mint may be selected from the following mint varieties: corn mint (Mentha arventis), grapefruit mint (Mentha c.v.), Egyptian mint (Mentha niliaca), peppermint (Mentha piperita), lime mint (Mentha piperita citrata c.v.), chocolate mint (Mentha piperita c.v.), curly mint (Mentha spicata crispa), wild mint (Mentha cardifolia), horse mint (Mentha longifolia), pineapple mint (Mentha suaveolens variegata), pennyroyal mint (Mentha pulegium), English spearmint (Mentha spicata c.v.) and apple mint (Mentha suaveolens).

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

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

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

In some embodiments, the substance delivered includes a fragrance.

As used herein, the terms "flavoring agent" and "flavoring agent" refer to materials that can be used, where permitted by local regulations, to create a desired taste, aroma, or other somatic sensation in products for adult consumers. They include naturally occurring flavoring materials, botanical substances, extracts of botanical substances, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, and the like). fruit, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberries, mulberries, citrus fruits, drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel quid, shisha, pineapple, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine , ylang-ylang, sage, fennel, wasabi, allspice, ginger, coriander, coffee, hemp, mint oil from any species of Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, laurel, 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, curcuma, cilantro, myrtle, black currant, valerian, allspice, melon, cereals, damien, marjoram, olive, lemon balm, lemon basil, chives, Calvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter receptor site blockers, sensory receptor site activators or stimulants, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, 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, e.g., liquids such as oils, solids such as powders, or gases.

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

In some embodiments, the flavoring may include sensory agents intended to achieve somatic sensations that are typically chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of the scent or taste nerves, and these may include agents that produce heating, cooling, tingling, and numbing effects. 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.

The aerosol-generating material may include or be an "amorphous solid." In some embodiments, the aerosol-generating material includes an aerosol-generating film that is an amorphous solid. The amorphous solid may be a "monolithic solid." The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dry gel. The amorphous solid is a solid material that can hold some fluid therein, such as a liquid. In some embodiments, the amorphous solid may include, for example, about 50 wt%, 60 wt%, or 70 wt% amorphous solid to about 90 wt%, 95 wt%, or 100 wt% amorphous solid. The aerosol-generating material may also be referred to as an aerosolizable material.

The aerosol-generating materials may include one or more active substances and/or fragrances, one or more aerosol-forming materials, and optionally one or more other functional materials.

The aerosolizable material may be present on a substrate. The substrate may be or include, for example, paper, card, paperboard, cardboard, recycled aerosolizable material, plastic material, ceramic material, composite material, glass, metal, or alloy.

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

The one or more other functional ingredients may include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and/or an antioxidant.

A consumable is an article that includes or consists of an aerosol-generating material, some 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 material storage area, an aerosol-generating material transfer part, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and/or an aerosol modifier. A consumable may also include an aerosol generator, such as a heater that releases heat so that the aerosol-generating material generates an aerosol upon use. The heater may include, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

A susceptor is a material that can be heated by the penetration of a varying magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, such that the penetration of the varying magnetic field results in inductive heating of the heat-generating material. The heat-generating material may be a magnetic material, such that the penetration of the varying magnetic field results in magnetic hysteresis heating of the heat-generating material. The susceptor may be both conductive and magnetic, such that the susceptor can be heated by either heating mechanism. A device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

An aerosol modifier is a substance that is typically located downstream of the aerosol-generation region and configured to modify the generated aerosol, for example by changing the taste, flavor, acidity, or another characteristic of the aerosol. The aerosol modifier may be provided within an aerosol modifier-releasing component 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 include, for example, one or more of a flavoring, a colorant, water, and a carbon adsorbent. The aerosol modifier may be, for example, a solid, liquid, or gel. The aerosol modifier may be in powder, string, or granular form. The aerosol modifier may not include a filtration material.

The aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to expose the aerosol-generating material to thermal energy to release one or more volatiles from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from the aerosol-generating material without heating. For example, the aerosol generator may be configured to expose the aerosol-generating material to one or more of vibration, high pressure, or electrostatic energy.

The aerosol-generating materials described herein include blends. A blend can be described as a mixture of two or more substances. For example, a blend may include two or more different types of tobacco, such as Virginia and Oriental. The blends described herein may include two or more different forms of tobacco, for example, a blend may include cut tobacco and reconstituted tobacco. Blends are typically mixed to be homogeneous.

The aerosol-generating material may contain additional components that are not part of the blend.

In some embodiments, the aerosol-generating material consists essentially of or consists of the blend.

The laminar tobacco described herein may also be referred to as leaf tobacco. The tobacco that may be used in the aerosol-generating materials described herein may be any suitable tobacco, such as a single grade or blend including Virginia (flue-cured and/or air-cured) and/or Burley and/or Oriental, cut rag or whole leaf. The aerosol-generating materials may include mixtures of any of these leaf tobacco materials.

The lamina tobacco is present in an amount of at least 20% by weight of the blend. For example, the lamina may be present in an amount of about 20% to about 90%, about 25% to about 85%, about 30% to about 70%, about 32% to about 65%, about 34% to about 60%, about 36% to about 55%, about 38% to about 50%, about 38% to about 45%, about 38% to about 42% by weight of the blend. In some embodiments, the lamina is present in an amount of about 40% by weight of the blend.

In some embodiments, the lamina is present in an amount of at least 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40% by weight of the blend.

In some embodiments, the lamina is present in an amount of 40%, 39%, 38%, 37%, 36%, 35%, 34%, 33%, 32%, 31%, or less than 30% by weight of the blend.

For the materials described herein, where amounts are given as % by weight, for the avoidance of doubt, this is on a total weight basis, unless specifically indicated to the contrary.

Where specifically stated, amounts may be given in weight percent based on dry weight. When based on dry weight, any water that may be present in the material/composition, or any component thereof, is completely ignored for purposes of determining weight percent. The water content of the materials/compositions described herein may vary, for example, from 5 to 15 weight percent. The content of the materials/compositions described herein may vary depending, for example, on the temperature, pressure, and humidity conditions under which the material/composition is maintained. The water content may be determined by Karl-Fischer analysis, as described herein.

According to one aspect, there is provided an aerosol-generating material comprising a blend, the blend comprising at least 20% laminar tobacco by weight of the blend. The aerosol-generating material is in the form of discrete particles.

The inventors have found that the form in which the aerosol-generating material is provided can result in variable or controllable aerosol generation when heated. In particular, the inventors have determined that when the aerosol-generating material comprises a blend of discrete particles that includes at least 20% laminar tobacco by weight of the blend, the release of aerosol-forming agents, such as glycerol and nicotine, can be delayed until later in the session.

Without wishing to be bound by any particular theory, it is believed that the individual particles are denser than typical aerosol-generating materials, such as 100% reconstituted tobacco, resulting in a lower/slower release rate of the aerosol-forming agents, such as nicotine and glycerol.

Further advantages may be observed when the discrete particles are used in consumables that are much shorter than conventional consumables, such as demi-slims. Shorter consumables, due to their smaller size, will necessarily contain less substrate, which may adversely affect sensory and/or organoleptic properties. The provision of discrete particles that release nicotine and aerosol forming agent more slowly may therefore result in a more pleasant experience for the consumer.

The aerosol-generating material may comprise, by weight of the aerosol-generating material, tobacco material in an amount of about 65% to about 85%; water in an amount of about 1% to about 10%; and aerosol-forming material in an amount of about 10% to about 30%. Preferably, the aerosol-generating material comprises, by weight of the aerosol-generating material, tobacco material in an amount of about 75%; water in an amount of about 4%; and aerosol former in an amount of about 20%.

In some embodiments, the blend includes reconstituted tobacco. The reconstituted tobacco may be paper reconstituted tobacco. Paper reconstituted tobacco refers to a tobacco material formed by a process in which a tobacco feedstock is extracted with a solvent to obtain an extract of soluble substances and a residue containing fibrous material, and then the extract (usually after concentration, optionally after further processing) and the fibrous material from the residue (usually after removing impurities from the fibrous material, optionally with the addition of some non-tobacco fiber) are recombined by depositing the extract onto the fibrous material. The recombination process is similar to a papermaking process.

The reconstituted tobacco may be any type of reconstituted tobacco known in the art. In certain embodiments, the reconstituted tobacco may be made from a feedstock including one or more of tobacco shreds, tobacco stems, and whole leaf tobacco. In further embodiments, the paper reconstituted tobacco is made from a feedstock consisting of tobacco shreds and/or whole leaf tobacco, and tobacco stems. However, in other embodiments, shreds, fines, and winnowers may alternatively or additionally be used in the feedstock.

Reconstituted tobacco for use in the blends described herein may be prepared by methods for preparing reconstituted tobacco known to those skilled in the art.

In some embodiments, the reconstituted tobacco is present in the blend in an amount of about 10% to about 90% by weight of the blend. For example, the reconstituted tobacco may be present in an amount of about 20% to about 80%, about 30% to about 75%, about 40% to about 70%, about 50% to about 70%, about 55% to about 65%, about 58% to about 64%, or about 58% to about 62%. In some embodiments, the reconstituted tobacco is present in an amount of about 60% by weight of the blend.

In some embodiments, the reconstituted tobacco is present in an amount of 80%, 79%, 78%, 77%, 76%, 75%, 74%, 73%, 72%, 71%, 70%, 69%, 68%, 67%, 66%, 65%, 64%, 63%, 62%, 61% or 60% by weight of the blend.

In some embodiments, the reconstituted tobacco is present in an amount of 80% or less, 79% or less, 78% or less, 77% or less, 76% or less, 75% or less, 74% or less, 73% or less, 72% or less, 71% or less, 70% or less, 69% or less, 68% or less, 67% or less, 66% or less, 65% or less, 64% or less, 63% or less, 62% or less, 61% or less, or 60% or less by weight of the blend.

In some embodiments, the blend comprises about 20% laminator tobacco and about 80% reconstituted tobacco by weight of the blend. For example, the blend comprises about 30% laminator tobacco and about 70% reconstituted tobacco, about 35% laminator tobacco and about 65% reconstituted tobacco, or about 40% laminator tobacco and about 60% reconstituted tobacco by weight of the blend.

In some embodiments, the blend consists of laminar tobacco and reconstituted tobacco.

In some embodiments, the blend comprises laminar tobacco, reconstituted tobacco, and flavorings. In some embodiments, the blend comprises 1% or less flavorings based on the weight of the blend.

The reconstituted tobacco material may have a density of less than about 700 milligrams per cubic centimeter (mg/cc). For example, the reconstituted tobacco material has a density of less than about 600 mg/cc. Alternatively or additionally, the reconstituted tobacco material has a density of at least 350 mg/cc.

The tobacco composition includes an aerosol-forming material. In this regard, an "aerosol-forming material" is a substance that facilitates the generation of an aerosol. The aerosol-forming material may facilitate the generation of an aerosol by promoting the initial vaporization and/or condensation of a gas to obtain an inhalable solid and/or liquid aerosol. In some embodiments, the aerosol-forming material may improve the delivery of flavorants from the aerosol-forming material.

In general, any suitable aerosol forming material or agent may be included in the aerosol generating materials of the present invention. Suitable aerosol forming materials include, but are not limited to: polyols, such as sorbitol, glycerol, and glycols, such as propylene glycol or triethylene glycol; non-polyols, such as monohydric alcohols, high boiling point hydrocarbons, acids, such as lactic acid, glycerol derivatives, esters, such as diacetin, triacetin, triethylene glycol diacetate, myristate esters, including triethyl citrate or ethyl and isopropyl myristate, and aliphatic carboxylate esters, such as methyl stearate, dimethyl dodecanedioate, and dimethyl tetradecanedioate. In a preferred embodiment, the aerosol forming material is selected from the group consisting of: glycerol, sorbitol, propylene glycol, triethylene glycol, lactic acid, diacetin, triacetin, triethylene glycol diacetate, triethyl citrate, ethyl myristate, isopropyl myristate, methyl stearate, dimethyl dodecanedioate, dimethyl tetradecanedioate, and mixtures thereof.

Aerosol-forming materials have been found to improve the sensory performance of articles for use in aerosol generating devices that contain tobacco compositions by aiding in the transfer of compounds, such as flavor compounds, from the tobacco material to the consumer.

In some embodiments, the aerosol-forming material may be glycerol, propylene glycol, or a mixture of glycerol and propylene glycol. Preferably, the aerosol-forming material comprises glycerol. Glycerol may be present in an amount of 10-20% by weight of the tobacco material, such as 13-16% by weight of the composition, or about 14% or 15% by weight of the material. Propylene glycol, when present, may be present in an amount of 0.1-0.3% by weight of the material.

According to a first aspect, the aerosol-generating material is in the form of discrete particles. The discrete particles can be molded, cast, compressed, extruded, or otherwise formed into a desired shape. In some embodiments, the discrete particles are in the form of beads or pellets. The discrete particles, such as beads or pellets, can have a smooth, regular external shape (e.g., spherical, cylindrical, ovoid, etc.) and/or they can have an irregular external shape.

In some embodiments, the individual particles are in the form of substantially spherical beads, with each bead having a diameter ranging from about 0.5 mm to about 3 mm, e.g., from about 1 mm to about 3 mm, about 1.5 mm to about 2.5 mm, as measured by sieving. In some embodiments, each bead has a mean average diameter, as measured by sieving, of about 0.5 mm, about 1 mm, about 1.5 mm, about 2 mm, about 2.5 mm, or about 3 mm.

The particles may have a size selected to produce a denser aerosol-generating material, which will affect heat transfer and release of volatile components within the material.

In some embodiments, the beads are formed by extrusion. Extrusion involves feeding a composition (also referred to herein as a blend) through a die to obtain an extrudate. This process applies pressure to the blend/composition in combination with shear forces.

Extrusion can be carried out using one of the major classes of extruders: screw, sieve and basket, roll, ram and pin barrel extruders. Single screw or twin screw extruders may be used. Forming tobacco beads by extrusion has the advantage that the process combines compression, mixing, conditioning, homogenization and shaping of the composition.

In some embodiments, during extrusion, a free-flowing composition including particles, such as lamina and/or reconstituted tobacco particles, is subjected to high pressure and temperature and forced through an orifice, such as a shaping nozzle or extrusion die, to form an extrudate. In some embodiments, the extrudate has a rod-like morphology and can be divided into segments of a desired length.

In some embodiments, the blend/composition is exposed to a temperature of about 40°C to about 150°C, or about 80°C to about 130°C, or about 60°C to about 95°C in the extruder. In some embodiments, including those using dual extrusion, the precursor blend/composition is exposed to a temperature of about 70°C to about 95°C in the extruder. In some embodiments, including those using single extrusion, the precursor composition is exposed to a temperature of about 60°C to about 80°C in the extruder.

In some embodiments, extrusion may be a generally dry process and the blend/composition comprises dry or substantially dry aerosol-generating particles. The blend/composition may optionally include other particulate materials including, for example, bases, diluents, solid aerosol formers, solid flavor modifiers, etc.

In some embodiments, a liquid may be added to the composition prior to or during the extrusion process. For example, water may be added, e.g., as a processing aid, to aid in dissolving or solubilizing the components of the composition, or to aid in binding or cohesion. Alternatively or additionally, a wetting agent may be added to the blend/composition.

In some embodiments, the liquid may be an aerosol-forming material, such as glycerol or others discussed herein. When the liquid is added to the composition in this manner, not only is the liquid applied to the surface, but as a result of the extruder pressure combined with the vigorous mixing due to the high shear forces, the extrudate becomes impregnated with the liquid. If the liquid is an aerosol-forming material, this may result in a high utilization of the aerosol-forming material in the resulting beads to promote evaporation of the volatile components.

For example, in some embodiments, the extruded aerosol generating material is spheronized. In spheronization, the extruded cylindrical particles are divided into uniform lengths and gradually transformed into spherical shapes by plastic deformation. If the extrudate is first divided into uniform lengths, the spheronization step will produce spheres with uniform diameters.

According to one specific example of the embodiments discussed herein, a sample of aerosol-generating material was produced as follows:

The tobacco was ground to produce a fine powder, taking care not to overheat the tobacco. The ground tobacco particles were sieved to select the desired size, e.g., less than 250 μm, less than 100 μm, or less than 60 μm.

Next, all of the dry (non-liquid) ingredients of the formulation were combined and mixed or blended in a mixer. In this particular case, the mixture was mixed for 1 minute at speeds up to 75 RPM. This ensured that the dry ingredients were evenly dispersed within the mixture.

Next, half the glycerol and half the water were added to the dry mix and mixed. Specifically, the mix was mixed for an additional minute at 75 RPM. The remaining glycerol and water were then added and mixed again for 1 minute at 75 RPM. Mixing was then continued until the mix was of a crumbly consistency so that it could be compressed into a mass to ensure a homogenous mix was achieved. In this particular case, additional mixing lasted for 3 minutes.

The mixture was then extruded using a Caleva MultiLab. A variety of different speeds and times were used, e.g., speeds from 1,500 to 2,500 and times from 1 to 5 minutes, to produce different extrudates.

The extrudate naturally broke into random lengths upon exiting the extruder and was subsequently spheronized. Spheronization was carried out until spherical beads were formed. In this case, the extrudate was first spheronized using a Caleva Multi Lab at 2,500 RPM for 1 minute and the beads were then inspected for any defects. Spheronization was then continued for an additional 1-2 minutes. The spheronization step broke the extruded material into individual pieces and beads were formed.

In the final step, the spheronized beads were dried in an oven at 65°C for 30 minutes. After each drying period, the beads were weighed and drying was stopped when the desired moisture weight loss was achieved. Generally, such drying takes about 1 hour.

According to embodiments, an article is provided that includes an aerosol-generating material as described herein and is configured to heat the material and generate an aerosol for use in an aerosol delivery device, such as a non-combustion aerosol delivery device.

In some embodiments, the aerosol delivery device is configured to accommodate at least a portion of an article for use in the aerosol delivery device that includes an aerosol generating material, heat the portion of the article for use in the aerosol delivery device that includes the material, and generate an aerosol from the material.

According to a second aspect, there is provided an article for an aerosol delivery system comprising a first aerosol generating material in a first form and a second aerosol generating material in a second form, the first and second aerosol generating materials being prepared from the same blend, and the first and second forms being different.

Without wishing to be bound by any particular theory, it is believed that providing an article with two regions containing ingredients produced from the same blend but in different forms may provide a more consistent taste profile upon ingestion.

Referring to FIG. 1, which is a longitudinal cross-section of an aerosol-generating rod. The rod includes a first aerosol-generating material 3 in a first form, such as beads, and a second aerosol-generating material 4 in a second form. In this embodiment, the first and second aerosol-generating materials are homogeneously mixed.

An alternative structure is illustrated in Figures 2 and 3, where the rod includes a first region 1 containing a first aerosol-generating material 3 of a first form and a second region 2 containing a second aerosol-generating material 4 of a second form.

In some embodiments, the first aerosol generating material is disposed in a first region and the second aerosol generating material is disposed in a second region. For example, the first aerosol generating material may be disposed closer to the mouthpiece of the device than the second aerosol generating material. Alternatively, the first aerosol generating material may be disposed farther from the mouthpiece than the second aerosol generating material. The first and second aerosol generating materials may be disposed adjacent to each other, or they may be disposed apart from each other.

Figure 4 illustrates a longitudinal cross-sectional view of an article for use in an aerosol delivery system including two regions 1, 2 of a first aerosol-generating material 3 and a second aerosol-generating material 4, and an additional mouth end section 5. The mouth end section 5 may be, for example, a plug of filter material such as tow or sheet material, optionally including cellulose acetate, paper, or other known materials.

5 is a longitudinal cross-sectional view of an article 11 for use in an aerosol delivery system including two regions 1, 2 of aerosol-generating material 3, 4 and a mouth end assembly. The mouth end assembly includes a series of adjacent sections: a spacer section 6, a cooling section 7, and a mouth end section 5. The sections of the article may be present in any order, not just the order shown. The spacer section is tubular and has a wall 7 and a central lumen 8. The wall 7 of the tubular spacer may include materials such as cellulose acetate, polylactide, or paper. The cooling section 6 may be any section having a shape and/or material that aids in cooling the vapor or aerosol generated when the aerosol-generating material 3, 4 is heated. The mouth end section 5 may again be a plug of filter material such as a tow or sheet material, optionally including cellulose acetate, paper, or other known materials.

Figure 6 shows an article 11 similar to the article of Figure 5, but including a tubular oral end section having a wall 9 and a central lumen 10.

In some embodiments, either the first aerosol-generating material or the second aerosol-generating material is in the form of discrete particles, as described herein.

In some embodiments, the first aerosol-generating material is in the form of discrete particles and the second aerosol-generating material is in the form of finely cut tobacco, as described herein. The discrete particles are relatively dense, meaning that they may take longer to heat up compared to finely cut material. The beads are at an optimal temperature to continue releasing these ingredients until the finely cut material is depleted, e.g., until all of its flavor/nicotine/aerosol-forming agents are depleted. The compositional characteristics of the beads may be similar to the finely cut materials, e.g., recon and lamina, such that any degradation of flavor and/or nicotine delivery is less noticeable.

In some embodiments, the first aerosol-generating material has a density at least about 25% higher than the density of the second aerosol-generating material, and optionally at least about 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, or 75% higher than the density of the second aerosol-generating material. The first aerosol-generating material may have a density not more than about 200% higher than the density of the second aerosol-generating material, and optionally not more than about 150%, 125%, 100%, or 75% higher than the density of the second aerosol-generating material. In some embodiments, the first aerosol-generating material has a density between about 25% and about 75% higher than the density of the second aerosol-generating material.

In some embodiments, the first aerosol-generating material has a density of at least about 0.4 g/cm ³ , and optionally at least about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, or 2 g/cm ^3. The first aerosol-generating material may have a density not greater than about 2 g/cm ³ , and optionally not greater than about 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1, 1, 0.9, 0.8, 0.7, 0.6, or 0.5 g/cm ^3. In some embodiments, the density of the first aerosol-generating material is between about 0.4 and 1.99 g/cm ³ .

In some embodiments, the second aerosol-generating material has a density of at least about 0.1 g/cm ³ , and optionally at least about 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, or 0.9 g/cm ^3. The second aerosol-generating material may have a density of no more than about 1 g/cm ³ , and optionally no more than about 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, or 0.2 g/cm ^3. In some embodiments, the density of the second aerosol-generating material is between about 0.1 and 0.9 g/cm ³ .

In some embodiments, the individual particles and the finely cut tobacco may be homogenously mixed. Without wishing to be bound by any particular theory, when the individual particles and the finely cut tobacco are homogenously mixed, the consumer may experience a more consistent taste delivery over the length of the session when using the device.

In some embodiments, the blend used in this second aspect is as described herein. In particular, the blend may include laminar tobacco and reconstituted tobacco as described in relation to the first aspect.

In some embodiments, the blend used in this second aspect is 100% laminar tobacco.

In some embodiments, the blend used in this second aspect comprises at least 20% laminar tobacco. For example, the blend may comprise 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39% or 40% laminar tobacco, based on the weight of the blend.

In some embodiments, the blend according to the second aspect comprises 80% or less reconstituted tobacco. For example, the blend may comprise 79%, 78%, 77%, 76%, 75%, 74%, 73%, 72%, 71%, 70%, 69%, 68%, 67%, 66%, 65%, 64%, 63%, 62%, 61%, or 60% reconstituted tobacco, based on the weight of the blend.

In some embodiments, the blend according to the second aspect comprises about 20% laminator tobacco and about 80% reconstituted tobacco by weight of the blend. For example, the blend comprises about 30% laminator tobacco and about 70% reconstituted tobacco, about 35% laminator tobacco and about 65% reconstituted tobacco, or about 40% laminator tobacco and about 60% reconstituted tobacco by weight of the blend.

Tobacco, such as laminar tobacco and reconstituted tobacco, described herein contains nicotine. In some embodiments, the nicotine content is 0.5-2% by weight of the tobacco, and may be, for example, 0.5-1.75%, 0.8-1.2%, or 0.8-1.75% by weight of the tobacco.

In some embodiments, the article according to the second aspect may be considered a consumable item and may be rod-shaped, such as a cylinder. In some embodiments, the article is cylindrical. In some embodiments, the first region and the second region are coaxially disposed along the rod.

In other embodiments, the first and second regions may have different dimensions. In some embodiments, the cylindrical region may have a cross-sectional diameter of at least about 5 mm, about 5.5 mm, about 6 mm, about 6.5 mm, about 7 mm, or at least about 7 mm to about 9 mm or less, about 8.5 mm, or about 8 mm or less.

In some embodiments, the article includes two sections, each having a length of at least about 15 mm, about 16 mm, about 17 mm, or about 18 mm, and not more than about 27 mm, about 26 mm, about 25 mm, or about 24 mm. In some embodiments, the first and second regions each have a length of about 17 to about 24 mm.

In some cases, the rod may include two sections, each having a length of about 15-20 mm, suitably about 18 mm. In some cases, the rod may include two sections, each having a length of about 22-27 mm, suitably about 24 mm.

In some embodiments, the laminar tobacco and the reconstituted tobacco have the same nicotine content.

In some embodiments, the aerosol-generating material includes one or more volatile components.

The aerosol-generating material is heated, irradiated or energized to generate an aerosol. The aerosol will include different components released from different components of the aerosol-generating material. For example, the aerosol-forming material will form an aerosol upon heating. In addition, the aerosol will include volatile components such as actives and flavors that are released upon heating. If the aerosol-generating material includes tobacco material, upon heating, volatile tobacco components including nicotine and flavors and aromas will be released and included in the aerosol formed from the aerosol-forming material.

The release of volatile components is generally temperature dependent and will therefore occur when the aerosol-generating material and the components therein reach a certain threshold temperature. Heat will generally spread or move through the material and therefore different parts or regions of the aerosol-generating material may be at different temperatures at a particular time. The spread or movement of heat through the aerosol-generating material will depend on a variety of factors including the density of the material.

The consumable or article is for use in an aerosol delivery assembly that includes an aerosol delivery device and the article.

In some embodiments, the aerosol delivery device may include a power source and a controller. The power source may be, for example, an electrical power source or a heat generating power source. In some embodiments, the heat generating power source includes a carbon substrate that may be energized to distribute electrical power in the form of heat to an aerosol generating material or heat transfer material proximate to the heat generating power source.

In some embodiments, the aerosol delivery system may include an area for receiving the article, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter, and/or an aerosol modifier.

In some embodiments, the assembly may be configured such that at least a portion of the aerosol-generating material is exposed to a temperature of at least 180° C. or 200° C. for at least 50% of the heating period. In some examples, the aerosol-generating material may be exposed to a thermal profile described in WO 2018/019855, the contents of which are incorporated herein in their entirety.

The assembly device includes a heating system configured to heat a first region containing a first aerosol generating material to a first peak temperature and to heat a second region containing a second aerosol generating material to a second peak temperature, where the second region reaches the second peak temperature after the first region reaches the first peak temperature.

In some embodiments, the heating of the second region to the second peak temperature occurs after the heating of the first region to the first peak temperature.

In some embodiments, the heating system may be configured such that, upon start of use, a first region of the article containing the first aerosol-generating material is immediately heated to a first peak temperature and the region of the article is maintained at the first peak temperature for a first period of time.

In some embodiments, the heating system may be configured such that, upon start of use, a second region of the article containing the second aerosol-generating material is immediately heated to a second peak temperature and the region of the article is maintained at the second peak temperature for a second period of time.

In other embodiments, the heating of the second region begins later than the heating of the first region. For example, the heating of the second region may begin only after the heating of the first region has finished. In some embodiments, there is no overlap between the heating of the first and second regions.

In some embodiments, the first peak temperature is at least about 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, or about 250° C. In some embodiments, the first peak temperature does not exceed about 350, 340, 330, 320, 310, 300, 290, 280, 270, 260, or about 250° C.

In some embodiments, the second peak temperature is at least about 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, or about 250° C. In some embodiments, the second peak temperature does not exceed about 350, 340, 330, 320, 310, 300, 290, 280, 270, 260, or about 250° C.

In some embodiments, the second peak temperature is higher than the first peak temperature. In some embodiments, the second peak temperature is about 10 to about 100° C. higher than the first peak temperature, or about 10 to 50° C., about 10 to 40° C., about 10 to 30° C., or about 10 to 20° C. higher than the first peak temperature.

The peak temperature of a region can be defined as the maximum temperature to which the region is heated. In some embodiments, the temperature of the region is measured as the temperature of the aerosol-generating material in the region. This temperature may be measured at a specific location in the region (preferably not directly adjacent to the heater) or may be calculated as the average temperature of the material throughout the region. In alternative embodiments, the temperature of the region is considered to be the temperature of the heater used to heat the region.

In some embodiments, the heating system includes one or more separate heaters configured to heat a first region of the article and one or more heaters configured to heat a second region of the article. The heaters are controlled by a heating system controller.

In some embodiments, the first region is heated to a first peak temperature and maintained for a period of about 10 seconds to about 300 seconds. In some embodiments, the first region is heated for a period of at least about 10 seconds, 20, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250, 260, 270, 280, or 290 seconds. In some embodiments, the first region is heated for a period of time not exceeding about 300 seconds, 290, 280, 270, 260, 250, 240, 230, 220, 210, 200, 190, 180, 170, 160, 150, 140, 130, 120, 110, 100, 90, 80, 70, 60, 50, 40, or 30 seconds. In some embodiments, the first region is maintained at the first peak temperature for a period of time of about 30 to about 120 seconds.

In some embodiments, the second region is heated to a second peak temperature and maintained for a period of about 10 seconds to about 300 seconds. In some embodiments, the second region is heated for a period of at least about 10 seconds, 20, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250, 260, 270, 280, or 290 seconds. In some embodiments, the second region is heated for a period of time not exceeding about 300 seconds, 290, 280, 270, 260, 250, 240, 230, 220, 210, 200, 190, 180, 170, 160, 150, 140, 130, 120, 110, 100, 90, 80, 70, 60, 50, 40, or 30 seconds. In some embodiments, the second region is maintained at the second peak temperature for a period of time of about 45 to about 240 seconds.

In some embodiments, the heating of the two or more regions of the article is coordinated to provide a relatively constant release of volatile compounds into the inhalable medium during the period of use of the aerosol delivery system. In some embodiments, the period of use may be about 300 seconds or less, or about 250 seconds or less. In some embodiments, the period of release of volatiles may be about 300 seconds or less, or about 250 seconds or less.

The heaters are configured to heat the regions to their respective peak temperatures. The heaters may also be configured to maintain the regions at the peak temperatures. Alternatively, or in addition, the heaters may be configured to maintain the regions at a lower temperature before and/or after the peak temperature is reached. In some known assemblies, two or more heaters are used and are arranged to heat different portions of the aerosol-generating material with the intention of not initially heating some of the aerosol-generating material, thereby reserving volatiles from that portion for consumption later in the product's useful life. However, in such assemblies, heat is released between the different heating zones, causing a reduction in volatiles in the zones where direct heating has not yet begun. This increases the delivery of such volatiles early in the consumption period and reduces the level of volatiles available for consumption later. Thus, the delivery of such volatile components is generally reduced on a puff-by-puff basis. However, the effect of such heat release can be reduced by including a second aerosol-generating material that is denser than the first aerosol-generating material. Denser materials heat up slower and heat spreads less through the material.

In some specific embodiments, the aerosol-generating material in the article or consumable weighs 260 mg and includes a combination of 130 mg of a first aerosol-generating material, e.g., including a blend of lamina and reconstituted tobacco, and 130 mg of a second aerosol-generating material, e.g., including higher density tobacco beads.

In some particular embodiments, the aerosol-generating material is rod-shaped and is formed from two cylindrical sections arranged coaxially along the rod of aerosol-generating material. In some examples, the cylindrical sections each contain about 20 to about 330 mg, or about 50 to about 300 mg, or about 40 to about 125 mg of tobacco, and are about 15 to about 20 mm, or about 18 mm in length. In some other examples, the cylindrical sections each contain about 100 to about 250 mg, or about 115 to about 235 mg of tobacco, and are about 22 to about 27 mm, or about 24 mm in length.

In some embodiments, the aerosol product may include the aerosol generating material and additionally a cooling element and/or a filter. If present, the cooling element may act or function to cool the gas or aerosol components. In some cases, the cooling element may act to cool the gas components so that they condense to form the aerosol. The cooling element also acts to space extremely hot parts of the device from the user. If present, the filter may include any suitable filter known in the art, such as a cellulose acetate plug.

The aerosol product may be surrounded by a packaging material such as paper. The aerosol product may further include ventilation openings. These 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 allow cooling air to be drawn into the article during use, where it can mix with the heated volatile components, thereby cooling the aerosol.

Ventilation increases the production of visible heated volatiles from the article when the article is heated during use. The heated volatiles are made visible by the process of cooling the heated volatiles such that supersaturation of the heated volatiles occurs. The heated volatiles then form droplets, otherwise known as nucleation, and ultimately the size of the aerosol particles of the heated volatiles increases due to further condensation of the heated volatiles and solidification of the newly formed droplets from the heated volatiles.

In some cases, the ratio of cooled air to the sum of heated volatiles and cooled air, known as the ventilation rate, is at least 15%. A ventilation rate of 15% allows the heated volatiles to be visualized by the methods described above. The visibility of the heated volatiles allows the user to confirm that volatiles are being produced and adds to the sensory experience of the smoking experience.

In another embodiment, the ventilation rate is between 50% and 85% to further cool the heated volatiles. In some cases, the ventilation rate may be at least 60% or 65%.

As used herein, an aerosol modifier is a substance that is typically disposed downstream of an aerosol-generation region and configured to modify the generated aerosol, for example by changing the taste, flavor, acidity, or another characteristic of the aerosol. The aerosol modifier may be provided in an aerosol modifier-releasing component 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 include, for example, one or more of a flavoring, a colorant, water, and a carbon adsorbent. The aerosol modifier may be, for example, a solid, liquid, or gel. The aerosol modifier may be in the form of a powder, strings, or granules. The aerosol modifier may not include a filtration material.

The various embodiments described herein are provided solely to aid in the understanding and teaching of the claimed features. These implementations are presented merely as representative examples of embodiments and are not all-inclusive and/or exclusive. The advantages, embodiments, examples, features, features, structures, and/or other aspects described herein should not be construed as limiting the scope of the invention as defined in the claims or to the equivalents of the claims, and it is understood that other embodiments may be utilized and changes may be made without departing from the scope of the invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. Furthermore, the present disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims (25)

An aerosol-generating material comprising a blend, the blend comprising at least 20% laminar tobacco by weight of the blend, the aerosol-generating material being in the form of discrete particles. The aerosol-generating material of claim 1, comprising tobacco material in an amount of about 65% to about 85% by weight of the aerosol-generating material, water in an amount of about 1% to about 10% by weight of the aerosol-generating material, and aerosol-forming material in an amount of about 10% to about 30% by weight of the aerosol-generating material. The aerosol-generating material of claim 1 or 2, comprising about 75% tobacco, about 4% water, and about 20% aerosol-forming material by weight of the aerosol-generating material. The aerosol-forming material of any one of claims 1 to 3, wherein the blend comprises at least about 30% laminar tobacco. The aerosol-forming material of any one of claims 1 to 4, wherein the blend further comprises reconstituted tobacco. The aerosol-forming material of claim 5, wherein the blend comprises about 80% or less reconstituted tobacco and about 20% or more laminar tobacco, by weight of the blend. The aerosol-forming material of claim 5 or 6, wherein the blend comprises about 60% to about 80% reconstituted tobacco and about 20% to about 40% laminar tobacco, by weight of the blend. The aerosol-forming material of any one of claims 5 to 7, wherein the blend comprises about 60% reconstituted tobacco and about 40% laminar tobacco by weight of the blend. The aerosol-generating material of any one of claims 1 to 8, wherein the particles are extruded, compressed or molded. The aerosol-generating material according to any one of claims 1 to 9, wherein the particles are beads or pellets. The aerosol-generating material of claim 10, wherein the beads or pellets are substantially spherical. The aerosol-generating material of claim 10 or 11, wherein the beads or pellets have a diameter of about 0.5 to about 3 mm. The aerosol-forming material of any one of claims 1 to 12, wherein the blend further comprises a flavoring agent. Use of the aerosol generating material according to any one of claims 1 to 13 in an article for use in a non-combustion aerosol delivery system. An article for use in a non-combustion aerosol delivery system comprising the aerosol generating material of any one of claims 1 to 13. A method for preparing an aerosol-forming material according to any one of claims 1 to 13, comprising the steps of:
grinding the initial tobacco blend to produce a grind blend;
mixing and extruding the ground blend to produce an extruded blend;
spheronizing the extruded blend to produce substantially spherical particles; and drying the substantially spherical particles. The method of claim 16, wherein the initial tobacco blend comprises reconstituted tobacco and laminar tobacco. The method of claim 16 or 17, wherein the grinding and mixing includes grinding the initial tobacco blend into particles smaller than 250 microns. The method of any one of claims 16 to 18, wherein mixing and extruding comprises mixing the milled composition, adding glycerol and water, and mixing until the mixture is homogenous. 20. The method of any one of claims 16 to 19, wherein drying comprises placing the particles in an oven at 65°C for about 30 to about 180 minutes. An article for an aerosol delivery system comprising a first aerosol generating material in a first form and a second aerosol generating material in a second form, the first and second aerosol generating materials being prepared from the same blend, and the first and second forms being different. 22. The article of claim 21, comprising an aerosol-generating section including a first region and a second region, the first aerosol-generating material being disposed in the first region and the second aerosol-generating material being disposed in the second region. The article of claim 21 or 22, wherein the first aerosol-forming material or the second aerosol-forming material is in the form of discrete particles, the discrete particles being extruded, compressed or molded, or the discrete particles being beads or pellets. An article for use in an aerosol delivery system comprising a first aerosol-generating material comprising a first blend in the form of discrete particles, and a second aerosol-generating material comprising a second blend, the first blend comprising at least 20% laminar tobacco by weight of the first blend, the second blend comprising at least 20% laminar tobacco by weight of the second blend, and optionally, the second blend in the form of fine cut tobacco. 25. The article of claim 24, wherein the individual particles are extruded, compressed or molded, and/or the particles are beads or pellets, and/or the first blend and the second blend comprise about 40% lamina and about 60% reconstituted tobacco.

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