WO2026013400A1

WO2026013400A1 - An Aerosol Generating Material

Info

Publication number: WO2026013400A1
Application number: PCT/GB2025/051518
Authority: WO
Inventors: Camila Assis; Fabio Carrer Andreis; Luciana Canova; Bruna Frielink Immich; Samuel KAISER; Tiago Linera do Canto; Liane Valadao Vieira Bokowski
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2024-07-10
Filing date: 2025-07-10
Publication date: 2026-01-15
Anticipated expiration: 2027-01-10
Also published as: EP4678015A1

Abstract

- 51 - Abstract An Aerosol Generating Material 5 An aerosol generating material comprising a tobacco material; and a non-tobacco botanical material; wherein the aerosol generating material produces an aerosol when heated, the aerosol having an odour activity value (OAV) of less than about 600. 10

Description

An Aerosol Generating Material

Technical Field

The present disclosure relates to an aerosol generating material and non-combustible aerosol-provision systems comprising the aerosol generating material.

Background

Aerosol generating materials are typically heated, for example by a non-combustible aerosol-provision system, to form an aerosol, which may be inhaled by a consumer. Aerosol generating materials may be made from various different sources, including from tobacco material and/or non-tobacco material.

Summary

According to a first aspect, there is described an aerosol generating material comprising: a tobacco material; and a non-tobacco botanical material; wherein the aerosol generating material produces an aerosol when heated, the aerosol having an odour activity value (OAV) of less than about 600.

According to a second aspect, there is described an aerosol generating rod comprising an aerosol generating material according to the first aspect.

According to a third aspect, there is described an article comprising the aerosol generating material according to the first aspect or the aerosol generating rod according to the second aspect.

According to a fourth aspect, there is described a delivery system comprising the aerosol generating rod according to second aspect or the article according to the third aspect.

Description of Drawings

Embodiments of the invention are described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 is a side-on cross-sectional view of an article for use with a non-combustible aerosol provision device. Detailed Description

As used herein, the term "aerosol generating material" describes a material that can generate an aerosol, for example when heated, irradiated, or energized in any other way. The aerosol generating materials described herein may take any suitable form and may be in reconstituted form, expanded form, cut strips, sheet form, a gathered sheet, extruded form, or any other appropriate form in the field. The aerosol generating material may be manufactured by any appropriate method used in the field, such as a paper-making process, a band casting method, and extruding.

The aerosol generating material may be incorporated into an article for use with a delivery system. An article is sometimes referred to as a consumable throughout this disclosure.

As used herein, the term "delivery system" is intended to encompass systems that deliver at least one substance to a user and includes non-combustible aerosol provision systems that release compounds from an aerosol-generating material without combusting the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials.

The article is for use in a non-combustible aerosol provision system. According to the present disclosure, a "non-combustible" aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.

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

The non-combustible aerosol provision system can be an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement.

The non-combustible aerosol provision system may be an aerosol-generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system. In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosolgenerating material and a solid aerosol-generating material.

Typically, the non-combustible aerosol provision system may comprise a noncombustible aerosol provision device and a consumable for use with the non- combustible aerosol provision device.

In some embodiments, the non-combustible aerosol provision system, such as a non- combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source.

In some embodiments, the non-combustible aerosol provision system comprises an area for receiving the article for use in the non-combustible aerosol-provision system, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent.

In an embodiment, the aerosol generating material is in the form of a rod. The aerosol generating rod may have a total weight of between about 250 mg and about 350 mg.

In an embodiment, the aerosol generating rod may be wrapped in a wrapper having a permeability of less than 100 Coresta Units. The aerosol generating rod may have an outer circumference of at least about 19 mm, preferably between about 19 mm and about 23 mm or about 21 mm. This may facilitate insertion of the article into an aerosol generation device.

As used herein, the term "rod" is used to describe a generally cylindrical element of substantially circular, oval, or elliptical cross section.

The aerosol generating material may comprise, or be, a continuous sheet of material. The sheet may be in the form of a wrapper, it may be gathered to form a gathered sheet or it may be shredded to form a shredded sheet. The shredded sheet may comprise one or more strands or strips of aerosol generating material. In the compositions described herein, where amounts are given in % by weight, for the avoidance of doubt this refers to a dry weight basis, unless specifically indicated to the contrary. Thus, any water that may be present in the aerosol-generating material, or in any component thereof, is entirely disregarded for the purposes of the determination of the weight %. The water content of the aerosol-generating material described herein may vary according to, for example, the temperature, pressure and humidity conditions at which the compositions are maintained. The water content can be determined by Karl-Fisher analysis, as known to those skilled in the art. On the other hand, for the avoidance of doubt, even when the aerosol-former material is a component that is in liquid phase, such as glycerol or propylene glycol, any component other than water is included in the weight of the aerosol-generating material.

In some embodiments, the aerosol generating material has a water content of between about 3% to about 15%. For example, the aerosol generating material has a water content of between about 3% and about 12%, such as between about 3% and about 10%, such as between about 3% and about 9%, such as between about 3% and about 8%, such as between about 4% to about 7%, for example between about 5% and about 6%. In some embodiments, the aerosol generating material comprises a water content of about 5%.

In some embodiments, the aerosol generating material has a filling value from about 2 cm³/g to about 10 cm³/g. In some embodiments, the aerosol generating material has a filling value of from about 3 cm³/g to about 8 cm³/g, for example the aerosol generating material may have a filling value of from about 4 cm³/g to about 7 cm³/g, such as from about 4 cm³/g to about 6 cm³/g. In some embodiments, the aerosol generating material has a filling value of about 5 cm³/g. When the filling value is between about 2 cm³/g to about 10 cm³/g, for example about 5 cm³/g, a consumable containing the aerosol generating material can achieve the same firmness using less material. Therefore, the overall weight of material used to achieve the same/required filling value, is less, which can provide a saving to the cost of goods.

Referring to Figure 1, the article 1 comprises a mouthpiece 2, and an aerosolgenerating section 3, connected to the mouthpiece 2. In the present example, the aerosol-generating section 3 comprises the aerosol-generating material. The article 1 comprises a downstream end 2b and an upstream end 2a distal from the downstream end 2b. In some embodiments, the aerosol generating material as described herein is provided in an aerosol generating section.

In the present example, the aerosol-generating material is circumscribed by a wrapper 5. In the present example, the wrapper 5 is a moisture impermeable wrapper. In some embodiments, the wrapper is paper, but may be made of alternative materials, such as aluminium.

The mouthpiece 2 includes a cooling section 6, also referred to as a cooling element, positioned immediately downstream of and adjacent to the source of aerosolgenerating material 3. In the present example, the cooling section 6 is in an abutting relationship with the source of aerosol-generating material 3. The mouthpiece 2 also includes, in the present example, a body of material 7 downstream of the cooling section 6, and a hollow tubular element 8 downstream of the body of material 7, at the mouth end of the article 1.

The aerosol-generating material may comprise or be in the form of an aerosolgenerating film. The aerosol-generating film may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and/or filler may also be present. The aerosol-generating film may be substantially free from botanical material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco free.

The aerosol-generating film may have a thickness of about 0.015 mm to about 1 mm. For example, the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm.

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

The aerosol-generating film may be discontinuous. For example, the aerosolgenerating film may comprise one or more discrete portions or regions of aerosolgenerating material, such as dots, stripes or lines, which may be supported on a support. In such embodiments, the support may be planar or non-planar. The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-former and one or more other components, such as one or more substances to be delivered, to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the aerosolgenerating film.

The slurry may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt% or 90 wt% of the solvent.

The aerosol-generating material may comprise or be an "amorphous solid". In some embodiments, the aerosol-generating materiel comprises 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 dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the amorphous solid may, for example, comprise from about 50wt%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% of amorphous solid.

The aerosol-generating film and/or amorphous solid may be substantially free from botanical material. The aerosol-generating film and/or amorphous solid may be substantially tobacco free.

In some embodiments, the non-tobacco botanical material may be selected from the list consisting of: oat, wheat, pea, flaxseed, apple, psyllium, ginger, jasmine, cocoa, bamboo, citrus, carob, rooibos, ginger, catuaba, green tea, maca, calamus, valerian, black tea, blackberry, rosehip, hibiscus, basil, chamomile, citron grass, lemon balm, passion flower, and combinations thereof.

In some embodiments, the non-tobacco botanical material is rooibos. When the first non-tobacco botanical material is rooibos, the aerosol generating material may comprise a second non-tobacco botanical material selected from the list consisting of: oat, wheat, pea, flaxseed, apple, psyllium, ginger, jasmine, cocoa, bamboo, citrus, carob, ginger, catuaba, green tea, maca, calamus, valerian, black tea, blackberry, rosehip, hibiscus, basil, chamomile, citron grass, lemon balm, passion flower, and combinations thereof.

Aerosol generating materials which produce aerosols with relatively few intense flavour compounds, may be of interest because such materials readily accept top flavours. Applying top flavours to a relatively neutral base substrate may facilitate the use of a greater variety of flavours. It may also enable more tailored flavour profiles to be developed, which can enhance the subtle underlying aromas generated by the nontobacco botanical material. For example, top flavours could be applied which enhance one of the specific aroma compounds discussed above. The non-tobacco botanical material may comprise relatively few aroma compounds compared to traditional tobacco material; therefore, an aerosol produced from a non-tobacco botanical material may have a different profile of volatile compounds compared to an aerosol produced from a tobacco material. Such aerosols may be considered favourable by a consumer of tobacco-based delivery systems. The aerosol generated from aerosol generating materials discussed herein may provide a sensorial experience that is comparable to that provided by a conventional combustible product, such as a cigarette.

Aerosol generating materials which produce aerosols with relatively intense flavour compounds may also be of interest. For example, a user may desire a particularly strong/intense experience and may therefore prefer that the aerosol generating material comprises botanical materials which produce strong/intense flavours/aromas.

In some embodiments, the aerosol generating material comprises a further non- tobacco botanical material, which may be selected from any suitable botanical material, such as: eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, Wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint may be chosen from the following mint varieties: Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Memtha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens.

Rooibos, i.e. Aspalathus linearis, is a member of the Fabaceae plant family and is grown in South Africa. Recently, rooibos has been granted a protected designation of origin status which restricts the name, rooibos, to only be used for Aspalathus linearis leaves cultivated in the Cederberg region of South Africa. For the avoidance of doubt, when referring to rooibos herein, it is intended to incorporate any plant material deriving from Aspalathus linearis. It is not intended to only include plant material originating from the Cederberg region of South Africa.

In some embodiments, the non-tobacco botanical material is a solid plant/plant-based material.

In some embodiments, wherein the aerosol generating material comprises rooibos, the rooibos is included in an amount of less than about 10 wt%, by weight of the aerosol generating material, such as less than about 20 wt%, less than about 30 wt%, less than about 40 wt%, less than about 50 wt%, less than about 60 wt%, less than about 70 wt%, less than about 80 wt%, based on the weight of the aerosol generating material.

As used herein, the term non-tobacco botanical material includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like.

In some embodiments, the aerosol generating material contains essentially 100% of the original non-tobacco botanical material. Utilising all of the botanical plant material is favourable as waste product is reduced. Furthermore, the full flavour profile of the original non-tobacco botanical material is maintained in the resulting aerosol generating material. This may be particularly favoured by consumers who may desire to consume an aerosol which has an aroma from a non-tobacco botanical material.

In some embodiments, the non-tobacco botanical material is included in an amount of from about 50 wt% to about 80 wt%, based on the total weight of the aerosol generating material. For example, the non-tobacco botanical material may be included in an amount of from about 55 wt% to about 80 wt%, such as from about 55 wt% to about 75 wt%, such as from about 60 wt% to about 75 wt%, such as from about 60 wt% to about 70 wt%, based on the total weight of the aerosol generating material.

In some embodiments, the non-tobacco botanical material is included in an amount of about 60 wt%, 61 wt%, 62 wt%, 63 wt%, 64 wt%, 65 wt%, 66 wt%, 67 wt%, 68 wt%, 69 wt%, 70 wt%, 71 wt%, 72 wt%, 73 wt%, 74 wt%, 75 wt%, 76 wt%, 77 wt%, 78 wt%, 79 wt%, 80 wt%, based on the total weight of the aerosol generating material.

In some embodiments, the non-tobacco botanical component is included in an amount of from about 30 wt% to about 55 wt%, based on the total weight of the aerosol generating material. For example, the first non-tobacco botanical component may be included in an amount of from about 35 wt% to about 55 wt%, such as from about 40 wt% to about 55 wt%, such as from about 45 wt% to about 55 wt%, such as from about 50 wt% to about 55 wt%, based on the total weight of the aerosol generating material.

In some embodiments, the non-tobacco botanical component is included in an amount of about 45 wt%, 46 wt%, 47 wt%, 48 wt%, 49 wt%, 50 wt%, 51 wt%, 52 wt%, 53 wt%, 54 wt%, 55 wt%, based on the total weight of the aerosol generating material.

In some embodiments, a ratio between the tobacco material and the non-tobacco botanical material is from about 10: 1 to about 1 : 10, from about 8: 1 to about 1 : 10, from about 10: 1 to about 8: 1, from about 8: 1 to about 1 :8, from about 6: 1 to about 1 :6, from about 5: 1 to about 1 : 5, from about 4: 1 to about 1 :4, from about 1 :3 to about 3: 1, from about 2: 1 to about 1:2, such as about 1 : 1.

In some embodiments, the maximum dimension of each particle of non-tobacco botanical material can be up to about 250 pm. In some embodiments, the maximum dimension of each particle of non-tobacco botanical material can be up to about 200 pm, such as up to about 150 pm, such as up to about 100 pm, such as up to about 75 pm. In some embodiments, the maximum dimension of each particle of non-tobacco botanical material can be up to about 1 mm, up to about 1.25 mm, up to about 1.5 mm.

A population of particles of non-tobacco botanical material may have a specific, targeted particle size distribution. Particle size distribution can be defined by referring to the D10, D50, and D90 values of a sample; and sieve analysis can be used to determine the particle size distribution of the particles of fibrous material.

In some embodiments, a population of particles of the non-tobacco botanical material may have a particle size distribution (D90) of at least about 100 pm. In some embodiments, a population of particles has a particle size distribution (D90) of at least about 110 pm, such as at least about 120 pm, such as at least about 130 pm, such as at least about 140 pm, such as at least about 150 pm.

In some embodiments, a population of particles of the non-tobacco botanical material may have a particle size distribution (D90) of at least about 200 pm, such as at least about 300 pm, such as at least about 400 pm, such as at least about 500 pm, such as at least about 600 pm, such as at least about 700 pm, such as at least about 800 pm, such as at least about 900 pm, such as at least about 1000 pm.

The particle size of the particulate non-tobacco botanical material can also influence the roughness of the sheet or shredded sheet of aerosol generating material.

In some embodiments, the aerosol generating material comprises an active and/or a flavourant.

An active as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropics, psychoactives. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise for example a nicotine source, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, CB1 and/or CB2 receptor agonists/antagonists, such as cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical.

The active substance may be a legally permissible recreational drug.

The active substance may comprise a nicotine source. In some embodiments, the active substance comprises caffeine, melatonin, or vitamin B12.

The active substance may comprise one or more constituents, derivatives, or extracts of cannabis, such as one or more cannabinoids or terpenes.

The active substance may be CBD or a derivative thereof.

The active may be derived from one of more botanicals, such as one or more of the botanicals described hereinabove. The active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof. The aerosol generating material comprises a tobacco material. As used herein, the term "tobacco material" refers to any material comprising tobacco or derivatives or substitutes thereof. The tobacco material may be in any suitable form. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. The tobacco material may comprise one or more of ground tobacco, tobacco fibre, cut tobacco, extruded tobacco, tobacco stem, tobacco lamina, and/or reconstituted tobacco.

By combining a tobacco material with a non-tobacco botanical material, one may be able to produce an aerosol which contains underlying tobacco flavours/aromas which may be desired by a consumer, but with reducing the total exposure to a tobacco material. For example, the inclusion of a non-tobacco botanical material may dilute the aerosol produced by a tobacco material, thereby retaining the underlying tobacco flavour but at a lower intensity.

The aerosol generating material comprises the tobacco material in an amount of less than about 90 wt%, based on the total weight of the aerosol generating material. For example, the aerosol generating material comprises less than about 85 wt% of tobacco material, less than about 80 wt%, less than about 75 wt%, less than about 70 wt%, less than about 65 wt%, less than about 60 wt%, less than about 55 wt%, less than about 50 wt%, less than about 45 wt%, less than about 40 wt%, less than about 35 wt%, less than about 30 wt%, less than about 25 wt%, less than about 20 wt%, less than about 15 wt%, less than about 10 wt%, less than about 9 wt%, less than about 8 wt%, less than about 7 wt%, less than about 6 wt%, less than about 5 wt%, less than about 4 wt%, less than about 3 wt%, less than about 2.5 wt%, less than about 2 wt%, less than about 1.5 wt%, less than about 1 wt%, based on the total weight of the aerosol generating material.

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

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

In some embodiments, the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucalyptol, WS-3 or WS-23.

The flavour may be in the form of a flavour composition which comprises or consists of the flavour. The flavour composition may comprise the flavour and one or more other components, such as a flavour, or a solvent, such as water, ethanol, isopropanol, n- butanol, ethyl acetate, isopropyl acetate, butyl acetate, anisole, glycerol or propylene glycol. The inclusion of a solvent in the flavour composition may improve the homogeneity of the flavour in the aerosol-generating material and improve the absorption or adsorption of the flavour into the aerosol-generating material.

In some embodiments, the active and/or flavourant is included in an amount of from about 0.5 wt% to about 10 wt%, based on the total weight of the aerosol generating material. For example, the active and/or flavourant may be included in an amount of from about 1 wt% to about 10 wt%, from about 1.5 wt% to about 10 wt%, from from about 1.5 wt% to about 9 wt%, from about 1.5 wt% to about 8 wt%, from about 1.5 wt% to about 7 wt%, from about 1.5 wt% to about 6 wt%, from about 1.5 wt% to about 5 wt%, from about 1.5 wt% to about 4 wt%, based on the total weight of the aerosol generating material.

In some embodiments, the aerosol generating material comprises an acid. For example, the acid may be selected from the list consisting of: levulinic acid, lactic acid, benzoic acid, citric acid, 2-methylbutyric acid, 2-methylvaleric acid, tartaric acid, and combinations thereof. In some embodiments, the acid is benzoic acid. In some embodiments, the acid is levulinic acid. In some embodiments, the acid is a combination of levulinic acid and benzoic acid.

The total amount of the acid may be from about 0.1% to about 5% by weight of the aerosol generating material. For example, the total amount of the acid is from about 0.1% to about 5%, from about 0.5% to about 5%, from about 1% to about 5%, from about 1.5% to about 5%, from about 2% to about 5%, or from about 2.5% to about 5% by weight of the aerosol generating material.

In some embodiments, the active comprises a nicotine salt, such as nicotine benzoate, nicotine citrate, nicotine lactate, nicotine levulinate, nicotine tartrate, nicotine bitartrate, nicotine hydrochloride, or combinations thereof. In some embodiments, the active may comprise a combination of nicotine salts, such as a combination of nicotine benzoate and nicotine levulinate.

In some embodiments, the aerosol generating material comprises an aerosol former/aerosol former material. The total amount of aerosol former may be from about 10% to about 20% by weight of the aerosol generating material. In some embodiments, the total amount of the aerosol former is from about 13% to about 16% by weight of the aerosol generating material. In some embodiments, the total amount of the aerosol former material is about 15% by weight of the aerosol generating material. When the aerosol generating material comprises an aerosol former in more than about 20%, by weight of the aerosol generating material, the aerosol generating may become "sticky" during storage, which may lead to processability issues.

In this context, an "aerosol former" is an agent, or material, that promotes the generation of an aerosol. An aerosol former may promote the generation of an aerosol by promoting an initial vaporisation and/or the condensation of a gas to an inhalable solid and/or liquid aerosol. In some embodiments, an aerosol former may improve the delivery of flavour from the aerosol generating material.

The aerosol former may improve the sensory performance of an article for use with an aerosol generation device comprising the aerosol generating material, by helping to transfer compounds such as flavour compounds from the fibrous material to the consumer. In some embodiments, the aerosol former material described herein is flavoured and/or comprises a flavour as described herein.

In general, any suitable aerosol former may be included in the aerosol generating material of the invention. Suitable aerosol formers include, but are not limited to: a polyol such as sorbitol, glycerol, and glycols like propylene glycol or triethylene glycol; a non-polyol such as monohydric alcohols, high boiling point hydrocarbons, acids such as lactic acid, glycerol derivatives, esters such as diacetin, triacetin, triethylene glycol diacetate, triethyl citrate or myristates including ethyl myristate and isopropyl myristate and aliphatic carboxylic acid esters such as methyl stearate, dimethyl dodecanedioate and dimethyl tetradecanedioate.

In some embodiments, the aerosol former is selected from the group consisting of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, propylene carbonate, and mixtures thereof.

In some embodiments, the aerosol former comprises glycerol in amount from about 10% to about 90% by weight of the aerosol former. Odour activity value (OAV) represents the potency of an aroma by comparing the concentration of an individual compound in a sample, such as an aerosol, and the threshold concentration of the individual compound, i.e. its odour threshold value or the minimal concentration that can be detected by a human nose. An OAV is calculated as the ratio of the concentration (pg per g) of an individual quantified compound in the sample and its corresponding aroma threshold value in water (pg per mL). Typically, more potent odorants have low odour detection thresholds, which means that they may be perceived by humans at low concentrations. OAV provides an estimate of the aroma intensity of each compound within a sample. OAV provides a reliable method for determining the contribution individual compounds, and their specific aromas have, on providing an overall, total aroma for a sample. OAV can be measured for individual compounds within a sample. In addition, a "total OAV" may be provided by collating the OAV of individual compounds within a sample. It is noted that measuring the total OAV of possible substrates for use as aerosol generating materials may enable fast screening of suitable materials. For example, when seeking to find an alternative substrate which provides a subtle/minimal flavour profile, one may seek a substrate which has a relatively low OAV. Alternatively, should one seek a substrate which has a dominating/strong aroma profile then substrates exhibiting relatively high total OAV may be preferred. OAV does not take into consideration the flavour compounds which may be generated from flavours loaded onto the aerosol generating material. OAV is representative of the underlying substrate.

The aerosol generating material produces an aerosol with a total odour activity value (OAV) of less than about 600. When the OAV of an aerosol is less than about 600, the aerosol may be described as having a favourable aroma profile. In particular, when an OAV of an aerosol is less than about 600 the aerosol has a relatively subtle underlying aroma/flavour. Consumers typically desire certain flavours to be contained within an aerosol and may dislike an aerosol with a very strong/overpowering aroma. Therefore, by ensuring that the OAV of the present aerosol generating material is below about 600, the aerosol generating material may be preferable to consumers.

In some embodiments, the aerosol generating material may produce an aerosol having an OAV of is less than about 550, such as less than about 500, such as less than about 450, such as less than about 400, such as less than about 350, such as less than about 300, such as less than about 250, such as less than about 200, such as less than about 150, such as less than about 100, such as less than about 75, such as less than about 50, such as less than about 25. An upper OAV limit may be of interest to ensure that no materials are incorporated into the aerosol generating material which may overpower other flavours/aromas.

In some embodiments, the aerosol generating material may produce an aerosol having an OAV of from about 150 to about 600, from about 200 to about 600, from about 225 to about 600, from about 250 to about 600, from about 300 to about 600, from about 350 to about 500, from about 400 to about 500.

In some embodiments, the aerosol generating material may produce an aerosol having an OAV of about 100, of about 200, of about 300, of about 400, of about 500, of about 600.

In the present disclosure, the inventors selected a group of 250 compounds, see Table 1, for analysis and determination of their OAV in different aerosol generating materials. It is thought that these 250 compounds represent a key group of aroma compounds of interest in an aerosol and provide a representative analysis of whether a non-tobacco botanical material exhibits a low/subtle aroma profile, or a strong/dominating aroma profile.

Table 1

In some embodiments, the OAV of each individual compound found in the aerosol is less than about 600, less than about 550, less than about 500, less than about 450, less than about 400, less than about 350, less than about 300, less than about 250, less than about 200, less than about 150, less than about 125, less than about 100, less than about 80, less than about 60, less than about 40, less than about 20, less than about 10. In some embodiments, the aerosol comprises at least one compound selected from the list consisting of: D-limonene, alpha-terpineol, benzeneacetic acid, levomenthol, menthol, 3-methyl butanoic acid, vanillin, 2-methoxy-4-vinylphenol, 2-methoxy phenol, maltol, terpinene-4-ol, 6-methyl-5-hepten-2-one, lH-pyrrole-2- carboxaldehyde, alpha-methyl-benzenemethanol, theobromine, octadecanoic acid, n- hexadecanoic acid, methyl-ester-hexadecanoic acid, butyrolactone, caffeine, 9- octadecenoic acid, furfural, 2-methyl butanoic acid, 2,3-dihydrobenzofuran, 2- heptadecanone, and combinations thereof. It is noted that aerosols containing these compounds may be particularly preferred by consumers. In particular, these compounds may have relatively subtle aromas which may be able to enhance, but not overpower, top flavours applied to an aerosol generating material. Therefore, botanical materials which produce these compounds when heated would represent particularly favoured substrates.

In some embodiments, the aerosol generating material comprises a first and second non-tobacco botanical material. When an aerosol generating material comprises two, or more, different non-tobacco botanical materials, one may be able to further tailor the aerosol. For example, if one seeks to provide an aerosol having a relatively subtle/minimal aroma profile they may combine two different non-tobacco botanical materials which have a combined OAV of less than a certain value. Combining different non-tobacco botanical materials in this manner facilities the ability to quickly arrive at suitable substrates, based on the preferred aroma characteristics of their aerosol.

In some embodiments, the aerosol generating material further comprises a fibrous material. For example, the aerosol generating material may comprise a further fibrous material such as wood fibres/wood pulp.

Used herein, wood fibre and wood pulp may be used to describe a cellulose material derived from a material which has little, or substantially no, noticeable aroma. For example, wood fibre and wood pulp may be of similar nature to wood fibre/wood pulp used to make paper. Wood fibre and wood pulp are typically obtained from a non- tobacco material. In some embodiments, the fibrous material has an OAV of less than about 5, such as less than about 4, less than about 3, less than about 2, less than about 1, less than about 0.5. In some embodiments, the fibrous material has an OAV of essentially zero.

Modifying the amount of an additional fibrous material, comprising for example, wood fibre/wood pulp, enables the aerosol to be modified/tailored to a specific desirable profile. For example, one may increase the relative amount of a non-tobacco botanical material, compared to wood fibre/wood pulp, therefore increasing the amount of aroma compounds derived from the non-tobacco botanical material in the aerosol.

By including an additional fibrous material with a relatively low OAV, one may be able to improve certain properties of the aerosol generating material, such as its structural characteristics, without negatively impacting the subtle flavours provided by the nontobacco botanical material.

In some embodiments, the aerosol generating material further comprises an extract. For example, the aerosol generating material may comprise an extract which is derived from the non-tobacco botanical material. As discussed above, certain nontobacco botanical materials may provide a favourable aroma profile. However, during processing, especially where heat may be applied, flavour compounds of higher volatility may be lost. Therefore, one may circumvent this problem by separating an extract from the non-tobacco botanical material prior to processing and reintroducing the extract into the aerosol generating material at a later stage of the manufacturing process when loss of the extract is less of a concern.

In some embodiments, the aerosol generating material has a thickness from about 250 pm to about 450 pm. In some embodiments, the aerosol generating material has a thickness from about 250 pm and about 400 pm, such as from about 280 pm to about 490 pm. In some embodiments, the aerosol generating material has a thickness of about 300 pm to about 400 pm. For example, the thickness may be from about 310 pm to about 390 pm. For example, the thickness may be from about 310 pm to about 380 pm. For example, the thickness may be from about 320 pm to about 370 pm. For example, the thickness may be from about 320 pm to about 360 pm. For example, the thickness may be from about 320 pm to about 350 pm. For example, the thickness may be from about 320 pm to about 340 pm. For example, the thickness may be from about 325 pm to about 340 pm. For example, the thickness may be from about 330 pm to about 340 pm.

In some embodiments, the aerosol generating material further comprises a filler. Where present, the filler may include one or more organic fillers, such as wood pulp, cellulose, cellulose derivatives (e.g. microcrystalline cellulose, methylcellulose, hydroxypropyl cellulose, and carboxymethylcellulose (CMC)) and a metal carbonate, such as calcium carbonate. In some embodiments, the aerosol generating material contains calcium carbonate, such as chalk. In some embodiments, the aerosol generating material does not contain calcium carbonate. In some embodiments, the filler is included in an amount of from about 5 wt% to about 20 wt%, based on the total weight of the aerosol generating material. For example, the filler may be included in an amount of from about 7 wt% to about 20 wt%, from about 7 wt% to about 18 wt%, from about 8 wt% to about 18 wt%, from about 8 wt% to about 16 wt%, from about 8 wt% to about 14 wt%, from about 8 wt% to about 13 wt%, from about 8 wt% to about 12 wt%, based on the total weight of the aerosol generating material.

In some embodiments, the filler is included in an amount of less than about 10 wt% based on the total weight of the aerosol generating material. For example, the filler may be included in an amount of less than about 9 wt%, such as less than about 8 wt%, less than about 7 wt%, less than about 6 wt%, less than about 5 wt%, less than about 4 wt%, less than about 3 wt%, based on the total weight of the aerosol generating material.

In some embodiments, the aerosol generating material comprises a binder. The binder is arranged to bind the components of the aerosol generating material. The aerosol generating material can comprise more than one binder. In such embodiments, the binders in the first composition can be the same or different.

The binder may be selected from one or more compounds selected from the group comprising alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica or silicones compounds, clays, polyvinyl alcohol and combinations thereof. For example, in some embodiments, the binder comprises one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose (CMC), pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol. In some cases, the binder comprises alginate and/or pectin or carrageenan. In some embodiments, the binder comprises CMC.

In some embodiments, the aerosol generating material is in an extruded form. An extruded material is a material which is prepared by mixing components to form a mixture and extruding the mixture using an extruder equipped with an orifice, such as a shaping die.

Extrusion may be performed using one of the main classes of extruders: screw, twin screw, sieve and basket, roll, and ram extruders. During extrusion the mixture may be exposed to elevated pressure when forced though the orifice to form an extruded material. In some embodiments, the extruded material has an elongated form and/or it may be cut into segments of a desired length as it exits the extruder. A rod-like extruded material may subsequently be cut into segments of desired length.

The extruded material may be shaped by the orifice or die through which it is forced. In some embodiments, the extruded material is cut into pieces of desired length. The pieces formed in this way may be used as aerosol generating components or they may undergo further processing. The orifice or die may be shaped to provide a strand of extruded material. For example, the extruded material may have the form of a cylindrical rod. Alternatively, the extruded material may have different cross-sectional shapes, including oval, polygonal (such as triangular, square, etc.), and stars.

The extruder may be operated without applying heat to the system (for example, at room/ambient temperature) or at an elevated temperature. Where the extruder is operated at an elevated temperature, the extruder may be operated at a temperature of up to about 200 °C. After the material exits the die of the extruder, it may be cooled, for example to room temperature, to provide the extruded material.

The mixture may be exposed to pressures ranging from about 2 bar to about 100 bar, or from about 5 bar to about 60 bar, depending on the design of the die being used.

Flavour may be applied to the extruded material. The flavour may be applied by applying a film of the flavour composition onto a surface of the material, spraying the flavour composition onto the material, applying droplets of the flavour composition onto a surface of the material or submerging the material in a solution comprising the flavour composition.

Liquids may be added to the mixture during the extrusion process. For example, water may be added to the mixture, for example as a processing aid to assist dissolution or solubilisation of components of the mixture, or to aid binding or agglomeration.

Alternatively, or additionally, a wetting agent may be added to the mixture.

The liquid may be an aerosol former material such as glycerol or others discussed herein, such as water. When liquid is added to the mixture in this manner, the liquid is applied not only on the surface, but, as a result of the extruder pressure combined with the intensive mixing by high shear forces, the extruded material becomes impregnated with the liquid. Where the liquid is an aerosol former material, this can result in a high availability of the aerosol former material in the extruded material to enhance evaporation of flavour components and other components of the final aerosol-forming material. Where the liquid is water, this may assist in the extrusion process, allowing a suitable/useable extruded aerosol generating material to be formed.

In some embodiments, the moisture content of the mixture is from about 5 wt% to about 15 wt%, such as from about 7 wt% to about 13 wt%, such as from about 10 wt% to about 12 wt%, based on the total weight of the mixture.

In some embodiments, the extruded material is formed into a desired shape selected to enhance or promote the release of active and/or flavour, for example by providing a form having a large surface area per unit volume. This large surface area may be provided on the outer surface of the extruded material, for example by selecting cross-sectional shapes with large perimeter.

The orifice or die may be shaped to provide an extruded material with inner channels. The presence of such inner channels provide further surface area and can enhance active and/or flavour release. The channel structure of the extruded aerosol generating material has enlarged inner surface area leading to improved heat and mass transfer. As a result, such components exhibit better, more uniform aerosol delivery. Furthermore, the structure with channels exhibits significantly improved strength in both the radial and axial directions, which is beneficial for the further processing of the aerosol generating material, for example when it is cut into segments and incorporated into a consumable.

The aerosol generating material may comprise, or be, a continuous sheet of material. The sheet may be in the form of a shredded sheet.

The aerosol generating material may be prepared by a papermaking process, including:

- mixing a portion of a non-tobacco botanical material with water in order to extract the water-soluble products contained therein;

- the water-soluble extract is separated from the fibrous portion by physical separation

- the fibrous portion is mixed with tobacco material and refined to produce a refined pulp, for example by chemically treating the fibrous portion - the refined pulp is passed into a papermaking machine in order to form a base sheet the sheet is impregnated with an active and/or flavourant; and

- the impregnated sheet is dried to form an aerosol generating material.

In some embodiments, the extract from the botanical material is reintroduced into the base sheet.

In some embodiments, impregnating the sheet comprises spraying a solution onto the sheet. For example, the solution may be sprayed onto the sheet by an electric sprayer or using a compressed air sprayer.

In some embodiments, the sheet is impregnated with active by passing the sheet through a bath comprising a solution. The sheet may be fully submerged into the solution bath such that the sheet is impregnated with active. Submerging the sheet in a solution bath may result in greater coverage of active on the sheet compared to simply spraying the sheet with solution.

In some embodiments, the sheet may be passed through a solution bath and sprayed with solution. For example, the sheet may be fully submerged in a solution bath, removed, and subsequently sprayed with a solution. Alternatively, the sheet may be submerged in a solution bath, removed, dried, and subsequently sprayed with solution.

In some embodiments, the extract, active and/or flavourant may be combined with the refined pulp in the papermaking machine, e.g. added to the slurry prior to forming the base sheet.

The active may be dissolved in a solvent to form the solution. A suitable solvent system would be readily identifiable to a skilled artisan depending on the properties of the active. For example, a hydrophilic active may be dissolved in an aqueous solvent. Suitable solvents include water. A lipophilic active may be dissolved in an organic solvent.

The impregnated sheet may be dried in a drying device, such as in a commercial air/steam drier.

The aerosol generating material may be cut into sheets, strips similar to strips of tobacco, or rolled into a roll that could be cut into webs for inclusion in a delivery system. In some embodiments, two or more sheets can be combined to form a laminate. For example, prior to drying, two or more sheets can be combined. For example, a first sheet may be combined with a second sheet made from the same non-tobacco botanical material to form a laminate. In some embodiments, a first sheet may be combined with a second sheet made from a different non-tobacco botanical material to form a laminate. Forming a laminate made from two different non-tobacco botanical materials may provide a desirable aerosol profile for a consumer. In some embodiments, a first sheet may be combined with a second sheet made from a tobacco material, such as a sheet of reconstituted tobacco. Combining a sheet made from a non-tobacco botanical material with a sheet made from tobacco material may enable the consumer to elevate the favourable/desirable aromas associated with an aerosol formed from a tobacco material.

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

The strands or strips of material may be formed by shredding the sheet of aerosolisable material. The sheet of aerosolisable material may be cut width-wise, for example in a cross-cut type shredding process, to define a cut length for the strands or strips of aerosolisable material, in addition to a cut width. The cut length of the shredded aerosolisable material is preferably at least 5 mm, for instance at least 10 mm, or at least 20 mm. The cut length of the shredded aerosolisable material can be less than 60 mm, less than 50 mm, or less than 40 mm.

In some embodiments, the aerosol generating material may be prepared by combining the tobacco material and the botanical material with an active and/or flavourant, a binder, and water to form a slurry. The slurry is subsequently processed to form a sheet of aerosolisable material. For example, the slurry may be processed by band casting it.

The slurry may be processed by forming a layer of the slurry on a surface and then drying the slurry to remove at least a portion of the water to form the sheet.

After drying, the sheet of aerosolisable material can be cut into strips or strands of aerosolisable material. The strips or strands of aerosolisable material can be gathered and formed into an article for use in a non-combustible aerosol provision system. A suitable process for cutting the sheet of aerosolisable material and gathering it into the article is found in WO 2019/057796. Optionally, the aerosolisable material can be crimped prior to being gathered and formed into the article.

In some embodiments, the sheet of aerosol generating material is processed into a bobbin. This bobbin of aerosol generating material may then be fed into a shredding apparatus, to form strands/ strips of aerosol generating material. Optionally, the aerosol generating material may be subject to a second cutting step, such as in a cross-cut type shredding process in order to obtain a defined cut length.

In some embodiments, the aerosol generating material may be prepared by processing the tobacco material and the non-tobacco botanical materials with a cellulose fibre. This process may comprise:

- Providing a pre-sized particulate tobacco and non-tobacco botanical material;

- Providing pre-sized cellulose fibre;

- Combining the pre-sized particulate tobacco material and non-tobacco botanical materials with the pre-sized cellulose fibre to provide an initial material, wherein the initial material comprises at least 50%, such as 60-75%, by mass, of the first and second non-tobacco botanical material, and preferably 5-20%, by mass, of cellulose fibre;

- Processing the initial material by setting the initial material to a predefined increased moisture content, subjecting the initial material to an increase in temperature and subjecting the initial material an increased pressure in order to bind the tobacco material and non-tobacco botanical material to the cellulose fibre;

- Feeding the initial material through a shearing gap to form an aerosol generating material; and

- Cooling the aerosol generating material.

Pre-sized particulate tobacco and non-tobacco botanical materials refers to material that has been subjected to a pre-sizing step prior to combining the botanical material with the cellulose fibre to form the initial material. The particle size reduction device may be a milling/cutting/shredding device. The size reduction device may be a disc mill. A hammer mill, or other milling device, may alternatively be used.

The pre-sizing step may comprise passing the tobacco and non-tobacco botanical materials through an appropriately sized sieve or series of sieves, and discarding, or processing to reduce the size of, any material that does not pass through the sieve or sieves, as appropriate. It has been found that pre-sizing the tobacco and non-tobacco botanical materials to provide the required particle size or particle size distribution improves the quality of the produced aerosol generating material, including the organoleptic qualities of the component or product.

Adjusting the specific particle sizes or size distribution also provides an approach for controlling and adjusting the filling power and density of the resulting aerosol generating material.

During processing, the initial material is subjected to increased mechanical pressure and in particular also increased temperature and moisture. The initial material is brought to a pre-defined increased moisture content. The material to be processed is also subjected to an increase in temperature, which may be obtained in particular by applying heat from outside and/or by mechanically generating pressure. In some embodiments, the initial material is heated to a temperature of in the range of 60- 180°C, such as 100-170°C, 120-160°C, or 130-150 °C.

This method of producing aerosol generating material has surprisingly been found to be advantageously performed at a lower expander pressure than that used in equivalent methods for processing tobacco material. Typically, corresponding tobacco processing methods require the use of expander pressures in the range of 35-50 bar. The production of equivalent materials comprising tobacco which do not include a binder typically require pressures of at least 60 bar, such as in the range of between 60 bar and 70 bar.

Advantageously, this processing method may comprise pressurising the initial material to a pressure in the range of 20-35 bar. This pressure is much lower than that used in the production of a corresponding material comprising only tobacco. Moreover, the use of lower pressures, such as less than 30 bar, or less than 25 bar, have been found to provide materials that are capable of carrying the greatest levels of aerosol forming materials.

As a result of the processing, the tobacco material, non-tobacco botanical material and cellulose fibre are bound together to produce an aerosol generating material that may be used subsequently for the production of aerosol provision systems. This obviates the need for expensive separate processes. Due to the mechanical pressure, the particles of the tobacco material, non-tobacco botanical material and cellulose fibre are pressed and bound together. As a result of this, the binding of the materials is so strong that the resulting aerosol generating material is resistant to the normal stresses which occur during subsequent processing. For example, botanical fines are not lost from the material as it is being conveyed by air under normal production conditions. Mechanical stability is therefore higher than is the case with conventional tobacco film materials.

The use of smaller particles of tobacco material and non-tobacco botanical materials, such as a higher proportion of botanical fines, in the initial material is advantageous because it means that small particles of botanical material, which are generally a waste by-product of manufacturing that would otherwise be disposed of, can instead be recycled and productively reused.

The use of smaller particles of non-tobacco botanical materials in the initial material is also advantageous because it has been found to increase the filling power of the material, particularly in combination with the use of a binder.

The processing preferably results in a product which is an aerosol generating material, in particular a fibrous and/or granular material or filler material. In other words, the method results in a product which is ready for consumption and can be used directly in an aerosol provision system. This is very different from producing a smokable material film (continuous material), which is more complex to produce and which still has to be cut and dried after production. The product obtained as a result of the present disclosure is of a size and moisture content which make it suitable for use directly as a filler material for aerosol provision systems, including tobacco heating devices.

On leaving the shearing gap and entering the atmosphere, a proportion of the entrained water evaporates abruptly which, in addition to the shearing effect, causes the material to be expanded in the shearing gap. The moisture of the material is reduced to be in the range of 5-25% such as 7-20%, or 8-15% due to the flash evaporation, depending on the process pressure and temperature, and ingredients contained in the material are also reduced to a certain extent.

It has been found to be advantageous if the shearing gap surfaces are moved relative to one another to prevent and clear blockages. This ensures that the full cross- sectional surface of the gap is used and constant physical conditions prevail at the gap, which ultimately results in a uniform product. To this end, it has also proved to be of advantage if the gap surfaces are structured or profiled, for example, having grooves.

Experimental

Sample Preparation

Botanical materials were dried, grinded using analytical mill (IKA All basic) and sifted through sieve of mesh 1.0 mm for further analysis. For GC-MS and CG x GC-TOFMS analysis, aliquots of powdered samples (200 ± 5 mg) were transferred to centrifuge tubes of 15 mL. The extraction was carried out with 5 mL of a mixture of chloroform/methanol (1 : 1) using sonication for 15 minutes followed by shaking at 200 rpm for 30 min. The samples were filtered throughout 0.22 pm filter (PTFE, Millipore®, USA) and transferred to vial for analysis. The samples were analysed in triplicate.

Particulate Phase Aerosol (PPA) extraction Consumable sticks were conditioned at 22 ± 1 °C and 60 ± 3 % relative humidity for 48 h to allow equilibration to occur.

For analysis the consumable sticks were volatilized using the Gio Hyper X3 device. Mainstream PPA was collected using a Cerulean SM 450 (Molins, UK) smoking machine under the Canadian smoking regime, two puffs per min, 2 s puff duration, 55 mL ± 0.2 mL puff volume, 30 s puff interval. The particulate phase from mainstream aerosol volatilized of 3 consumable sticks was collected by a 55 mm Cambridge pad and transferred to 50 ml Erlenmeyer.

Instrumental analysis

GC x GC (TOFMS) analysis

The calibration curve analyses were carried out by an Agilent 7890B gas chromatograph coupled with a 7200-series quadrupole-time-of-flight mass spectrometer (GC-QTOFMS, Agilent Technologies, USA). This system was retrofitted with a Zoex ZX2 cooled-loop GC x GC thermal modulator (Zoex Corporation, USA) - GC x GC-QTOFMS. Samples were injected in splitless mode at 250°C. For all the analyses, a non-polar 5% phenyl 95% methylpolysiloxane phase (30 m x 0.25 mm i.d. x 0.25 pm df) (DB-5ms, Agilent Technologies, USA) was used as the first dimension (ID) column. The second dimension (2D) was a mid-polar trifluoropropyl phase (10m x 0.10 mm i.d. x 0.15 pm df) (VF-200ms, Agilent Technologies, USA). The carrier gas was helium 1 mL min ¹. Chromatographic conditions were: initial temperature of 50°C (0.2 min) increased to 140°C (18.2 min) with a heating rate of 5°C min ¹; followed by an increase to 180°C (28.2 min) with a heating rate of 4°C min ¹, increased to 250°C (52.2 min) with a heating rate of 5°C min ¹, finally increasing to 280°C with a heating rate of 5°C min ¹ and a final isothermal period at 280°C for 5 min. Both columns operated at the same temperature. Modulation period, modulation duration, modulator hot jet program and modulator cold jet temperature were, respectively, 12 s, 0.6 s, 170°C, 5°C min ¹ to 370°C and -90 °C. The transfer line temperature was set at 290°C. A mass spectra range was from 33 to 500 m/z and ionization energy was 70 eV. The ion source was maintained at 250°C.

GC - MS analysis (DB-5ms)

The calibration curve analyses were carried out by Agilent 7890B gas chromatograph coupled with a 5977A MSD-series mass spectrometer detector (GC-MS, Agilent Technologies, USA). A 1 pL sample was injected into a non-polar 5% phenyl 95% methylpolysiloxane phase (30 m x 0,25 mm i.d. x 1 pm df) (DB-5ms, Agilent Technologies, USA) capillary column. Samples were injected in splitless mode at 250 °C using helium 1 mL min ¹ as carrier gas. Chromatographic conditions were: initial temperature of 50 °C (0.5 min) increased to 100 °C (17.17 min) with a heating rate of 3 °C min ¹; followed by an increase to 250 °C (42.17 min) with a heating rate of 10 °C min ¹, finally increase to 280 °C with a heating rate of 5 °C min ¹ and a final isothermal period at 280 °C for 5 min. The transfer line temperature was set at 290 °C. A mass spectra range was 33 to 500 m/z and ionization energy was 70 eV. The ion source and quadrupole were maintained at 300 °C and 150 °C respectively.

GC - MS analysis (DB-FFAP)

The calibration curve analyses were carried out by Agilent 7890B gas chromatograph coupled with a 5977A MSD-series mass spectrometer detector (GC-MS, Agilent Technologies, USA). A 1 pL sample was injected into a high polarity nitroterephthalic acid modified polyethylene glycol phase (30 m x 0,25 mm i.d. x 0.50 pm df) (DB- FFAP, Agilent Technologies, USA) capillary column. Samples were injected in splitless mode at 250 °C using helium 1.6 mL min ¹ as carrier gas. Chromatographic conditions were: initial temperature of 50 °C (0.5 min) increased to 100 °C (17.2 min) with a heating rate of 3 °C min ¹; followed by increased to 230 °C (42.2 min) with a heating rate of 10 °C min ¹; finally increase to 240 °C with a heating rate of 20 °C min ¹ and a final isothermal period at 240 °C for 4min. The transfer line temperature was set at 260 °C. A mass spectra range was 33 to 500 m/z and ionization energy was 70 eV. The ion source and quadrupole was maintained at 300 °C and 150 °C respectively. Analytical Data Processing GC x GC (TOFMS)

Volatile and semi-volatile chemical data (GC-MS total ion chromatogram) were converted from raw format to a structured form (mzXML extension) and aligned in time and mass dimensions. Each blob detected is deconvoluted and compared with NIST MS compound Database. In the end, each sample is represented by a volatile and semi-volatile fingerprint of compounds extracted from NIST with acceptable match factor (MF > 600), presence of two reference molecular ion (15 ppm mass error) and retention index (50 LRI).

Two hundred and fifty volatile chemical compounds, identified in Table 1, with sensory relevance were used for flavour decoding approach. For this, the compounds were quantified in volatile and semi-volatile fingerprint through linear regression and external calibration.

In addition, the odour activity values (OAV) were calculated to estimate the aroma intensity of each compound odorant. OAVs for each odorant were calculated as the ratio of the concentration (pg per g) of an individual quantified compound in the samples and its corresponding aroma threshold value in water (pg per mL).

MATLAB (MathWorks, USA), PLS toolbox (Eigenvector, USA) and Simca (Umetrics, Sweden) were used to perform statistical analysis. MS Converter (ProteoWizard, USA) was used to convert raw files in structure ones. Data acquisition and visualization of individual total ion chromatography (TIC) were performed using MassHunter workstation software (Agilent Technologies, USA).

GC - MS

Volatile and semi-volatile chemical data (GC-MS total ion chromatogram) were imported from Agilent Technologies MassHunter Unknowns Analysis (version B.09.00). The method in the software used the library NIST 2020 MS and the method was configured to identify compounds with minimum match factor of 70% and sharpness range threshold analysed was set between 10 - 25%. The parameters selected for batch of samples is "Component RT", "Compound Name", "Match Factor", "Formula", "CAS", "Component Area", "Component Height", "Sample Name", "File Name" and "Best Hit". Compounds were deconvoluted and evaluated from the first hit until the fifth hit. After analysis in the software, the data was exported to format "(*.xlsx)" and analysed through interpretation of the fragmentation profile per compound using spectrum data analysis tools and confirmed by retention index calculated. Two hundred and fifty volatile chemical compounds with sensory relevance were used for flavour decoding approach. For this, the compounds were quantified in volatile and semi-volatile fingerprint through linear regression and external calibration in the target method..

In addition, the odour activity values (OAV) were calculated, when possible, to estimate the aroma intensity of each compound odorant. OAVs for each odorant were calculated as the ratio of the concentration (pg per g) of an individual quantified compound in the samples and its corresponding aroma threshold value in water (pg per mL).

The methods described herein above follows the standard methods for determining OAV and would be known to a person skilled in the art of aroma analysis. Further information regarding OAV can be found in: (1) T.G. Schwanz, L.V. Bokowski, M.C. Marcelo, A.C. Jandrey, J.C. Dias, D.H. Maximiano, L.S. Canova, O.F. Pontes, G.P. Sabin, S. Kaiser, Analysis of chemosensory markers in cigarette smoke from different tobacco varieties by GCx GC-TOFMS and chemometrics, Taianta, 202 (2019) 74-89; and (2) T.G. Schwanz, M.G. Nespeca, J.C. Dias, L.V.V. Bokowski, M.C. A. Marcelo, D.H. Maximiano, L.S. Canova, P.B. de Souza Cruz, O.F.S. Pontes, S. Kaiser, GCx GC- TOFMS and chemometrics approach for comparative study of volatile compound release by tobacco heating system as a function of temperature, Microchemical Journal, (2020) 105578.

The following fibres were prepared and tested according to the process set out above:

Oat

Apple

Bamboo

Citrus

Cocoa

Flaxseed

Pea

Psyllium

Wheat

In addition to the above botanical materials, mixtures of botanicals were prepared and tested according to the methods discussed above:

Based on the above, it is clear that the overall aroma profile of an aerosol generated from an aerosol generating material can be modified based on the botanical materials included therein. The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc, other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.

Clauses

The following clauses are included as examples only.

1. An aerosol generating material comprising: a tobacco material; and a non-tobacco botanical material; wherein the aerosol generating material produces an aerosol when heated, the aerosol having an odour activity value (OAV) of less than about 600.

2. The aerosol generating material according to clause 1, wherein the non-tobacco botanical material is selected from the list consisting of: oat, wheat, pea, flaxseed, apple, psyllium, ginger, jasmine, cocoa, bamboo, citrus, carob, rooibos, ginger, catuaba, green tea, maca, calamus, valerian, black tea, blackberry, rosehip, hibiscus, basil, chamomile, citron grass, lemon balm, passion flower, eucalyptus, clove, cinnamon, lavender, and combinations thereof.

3. The aerosol generating material according to clause 1 or clause 2, wherein the non-tobacco botanical material is selected from the list consisting of: oat, bamboo, citrus, apple, rooibos, and combinations thereof.

4. The aerosol generating material according to any one of clauses 1 to 3, wherein the non-tobacco botanical material is rooibos.

5. The aerosol generating material according to any one of clauses 1 to 4, further comprising a second non-tobacco botanical material selected from the list consisting of: oat, wheat, pea, flaxseed, apple, psyllium, ginger, jasmine, cocoa, bamboo, citrus, carob, ginger, catuaba, green tea, maca, calamus, valerian, black tea, blackberry, rosehip, hibiscus, basil, chamomile, citron grass, lemon balm, passion flower, and combinations thereof, wherein the second non-tobacco botanical material is different to the first non-tobacco botanical material.

6. The aerosol generating material according to any one of clauses 1 to 5, wherein the odour activity value (OAV) is less than about 550, such as less than about 500, such as less than about 450, such as less than about 400, such as less than about 350, such as less than about 300, such as less than about 250, such as less than about 200, such as less than about 150, such as less than about 100, such as less than about 75, such as less than about 50, such as less than about 25.

7. The aerosol generating material according to any one of clauses 1 to 6, wherein the aerosol comprises at least one compound selected from the list consisting of: D- limonene, alpha-terpineol, benzeneacetic acid, levomenthol, menthol, 3-methyl butanoic acid, vanillin, 2-methoxy-4-vinylphenol, 2-methoxy phenol, maltol, terpinene-4-ol, 6-methyl-5-hepten-2-one, lH-pyrrole-2-carboxaldehyde, alpha- methyl-benzenemethanol, theobromine, octadecanoic acid, n-hexadecanoic acid, methyl-ester-hexadecanoic acid, butyrolactone, caffeine, 9-octadecenoic acid, furfural, 2-methyl butanoic acid, 2,3-dihydrobenzofuran, 2-heptadecanone, and combinations thereof.

8. The aerosol generating material according to any one of clauses 1 to 7, further comprising an active and/or a flavourant.

9. The aerosol generating material according to clause 8, wherein the active is selected from; a nicotine source, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof.

10. The aerosol generating material according to clause 9, wherein the nicotine source is a nicotine salt, such as nicotine benzoate, nicotine levulinate, nicotine lactate, nicotine citrate, nicotine tartrate, nicotine bitartrate, nicotine hydrochloride, and combinations thereof.

11. The aerosol generating material according to any one of clauses 1 to 10, wherein the tobacco material is included in an amount of from about 5 wt% to about 80 wt%, based on the total weight of the aerosol generating material. 12. The aerosol generating material according any one of clauses 1 to 11, wherein the non-tobacco botanical material is included in an amount of from about 5 wt% to about 80 wt%, based on the total weight of the aerosol generating material. 13. An aerosol generating rod comprising an aerosol generating material according to any one of clauses 1 to 12.

14. An article comprising the aerosol generating material according to any one of clauses 1 to 12 or the aerosol generating rod according to clause 13.

15. A delivery system comprising the aerosol generating rod according to clause 13 or the article according to clause 14.

Claims

2. The aerosol generating material according to claim 1, wherein the non-tobacco botanical material is selected from the list consisting of: oat, wheat, pea, flaxseed, apple, psyllium, ginger, jasmine, cocoa, bamboo, citrus, carob, rooibos, ginger, catuaba, green tea, maca, calamus, valerian, black tea, blackberry, rosehip, hibiscus, basil, chamomile, citron grass, lemon balm, passion flower, eucalyptus, clove, cinnamon, lavender, and combinations thereof.

3. The aerosol generating material according to claim 1 or claim 2, wherein the non-tobacco botanical material is selected from the list consisting of: oat, bamboo, citrus, apple, rooibos, and combinations thereof.

4. The aerosol generating material according to any one of claims 1 to 3, wherein the non-tobacco botanical material comprises rooibos.

5. The aerosol generating material according to any one of claims 1 to 4, further comprising a second non-tobacco botanical material selected from the list consisting of: oat, wheat, pea, flaxseed, apple, psyllium, ginger, jasmine, cocoa, bamboo, citrus, carob, ginger, catuaba, green tea, maca, calamus, valerian, black tea, blackberry, rosehip, hibiscus, basil, chamomile, citron grass, lemon balm, passion flower, and combinations thereof, wherein the second non-tobacco botanical material is different to the first non-tobacco botanical material.

6. The aerosol generating material according to any one of claims 1 to 5, wherein the odour activity value (OAV) is less than about 550, such as less than about 500, such as less than about 450, such as less than about 400, such as less than about 350, such as less than about 300, such as less than about 250, such as less than about 200, such as less than about 150, such as less than about 100, such as less than about 75, such as less than about 50, such as less than about 25.

7. The aerosol generating material according to any one of claims 1 to 6, wherein the odour activity (OAV) is about 100, is about 200, is about 300, is about 400, is about 500, is about 600.

8. The aerosol generating material according to any one of claims 1 to 7, wherein the aerosol comprises at least one compound selected from the list consisting of: D- limonene, alpha-terpineol, benzeneacetic acid, levomenthol, menthol, 3-methyl butanoic acid, vanillin, 2-methoxy-4-vinylphenol, 2-methoxy phenol, maltol, terpinene-4-ol, 6-methyl-5-hepten-2-one, lH-pyrrole-2-carboxaldehyde, alpha- methyl-benzenemethanol, theobromine, octadecanoic acid, n-hexadecanoic acid, methyl-ester-hexadecanoic acid, butyrolactone, caffeine, 9-octadecenoic acid, furfural, 2-methyl butanoic acid, 2,3-dihydrobenzofuran, 2-heptadecanone, and combinations thereof.

9. The aerosol generating material according to claim 8, wherein the odour activity value (OAV) of the at least one compound is less than about 600, less than about 550, less than about 500, less than about 450, less than about 400, less than about 350, less than about 300, less than about 250, less than about 200, less than about 150, less than about 125, less than about 100, less than about 80, less than about 60, less than about 40, less than about 20, less than about 10.

10. The aerosol generating material according to any one of claims 1 to 9, further comprising an active and/or a flavourant.

11. The aerosol generating material according to claim 10, wherein the active is selected from; a nicotine source, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof.

12. The aerosol generating material according to claim 11, wherein the nicotine source is a nicotine salt, such as nicotine benzoate, nicotine levulinate, nicotine lactate, nicotine citrate, nicotine tartrate, nicotine bitartrate, nicotine hydrochloride, and combinations thereof.

13. The aerosol generating material according to claim 11 or claim 12, wherein the nicotine source is nicotine benzoate.

14. The aerosol generating material according to claim 11 or claim 12, wherein the nicotine source is nicotine levulinate.

15. The aerosol generating material according to claim 11 or claim 12, wherein the nicotine source is a mixture of nicotine benzoate and nicotine levulinate.

16. The aerosol generating material according to claim 11, wherein the nicotine source is nicotine and an organic acid.

17. The aerosol generating material according to claim 16, wherein the organic acid is selected from lactic acid, levulinic acid, benzoic acid, citric acid, 2-methylbutyric acid, 2-methylvaleric acid, and combinations thereof.

18. The aerosol generating material according to any one of claims 1 to 17, further comprising an aerosol former.

19. The aerosol generating material according to claim 18, wherein the aerosol former is selected from glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, propylene carbonate, and combinations thereof.

20. The aerosol generating material according to claim 18 or claim 19, wherein the aerosol former is included in an amount of about 10% to about 20% by weight of the aerosol generating material.

21. The aerosol generating material according to any one of claims 1 to 20, wherein the tobacco material is included in an amount of from about 5 wt% to about 80 wt%, based on the total weight of the aerosol generating material.

22. The aerosol generating material according any one of claims 1 to 21, wherein the non-tobacco botanical material is included in an amount of from about 5 wt% to about 80 wt%, based on the total weight of the aerosol generating material.

23. The aerosol generating material according to any one of claims 1 to 22, wherein a ratio between the tobacco material and the non-tobacco botanical material is from about 10: 1 to about 1: 10, from about 8: 1 to about 1 : 10, from about 10: 1 to about 8: 1, from about 8: 1 to about 1 :8, from about 6: 1 to about 1:6, from about 5: 1 to about 1 : 5, from about 4: 1 to about 1 :4, from about 1 :3 to about 3: 1, from about 2: 1 to about 1 :2, such as about 1 : 1.

24. The aerosol generating material according to any one of claims 1 to 23, further comprising an extract.

25. The aerosol generating material according to claim 24, wherein the extract is derived from the tobacco material.

26. The aerosol generating material according to claim 24, wherein the extract is derived from the non-tobacco botanical material.

27. The aerosol generating material according to any one of claims 1 to 26, wherein the aerosol generating material has a thickness from about 200 pm to about 450 pm.

28. An aerosol generating rod comprising an aerosol generating material according to any one of claims 1 to 27.

29. An article comprising the aerosol generating material according to any one of claims 1 to 27 or the aerosol generating rod according to claim 28.

30. A delivery system comprising the aerosol generating rod according to claim 28 or the article according to claim 29.