WO2024241058A1

WO2024241058A1 - Aerosol-generating composition

Info

Publication number: WO2024241058A1
Application number: PCT/GB2024/051331
Authority: WO
Inventors: Jennifer Louise SCIROCCO; Biniam TESFATSION; Jack HUMPHREY; Klaus MATHIE
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2023-05-23
Filing date: 2024-05-23
Publication date: 2024-11-28
Anticipated expiration: 2025-11-23
Also published as: GB202307727D0; TW202510755A

Abstract

Disclosed herein is an aerosol-generating composition comprising: (i) a first material which comprises an acid and a binder, but does not comprise nicotine; and (ii) a second material which comprises a protonatable active; wherein the molar ratio of protonatable active to acid in the composition is about 4:1 or less; a consumable comprising the composition; and a method for preparing the composition.

Description

Aerosol-Generating Composition

Technical Field

The present invention relates to aerosol generation. In particular, the present invention relates to an aerosol-generating composition, a consumable, a non-combustible aerosol provision system, a method of generating aerosol and a method of forming an aerosol-generating composition.

Background

Smoking articles such as cigarettes, cigars and the like burn tobacco during use to create tobacco smoke. Alternatives to these types of articles release an inhalable aerosol or vapour by releasing compounds from a substrate material by heating without burning. These may be referred to as non-combustible smoking articles, aerosol generating assemblies or non-combustible aerosol provision systems.

One example of such a product is a heating device which release compounds by heating, but not burning, a solid aerosolisable material. This solid aerosolisable material may, in some cases, contain a tobacco material. The heating volatilises at least one component of the material, typically forming an inhalable aerosol. These products may be referred to as heat-not-burn devices, tobacco heating devices or tobacco heating products (THP). Various different arrangements for volatilising at least one component of the solid aerosolisable material are known.

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

Summary

In one aspect, there is provided an aerosol-generating composition comprising: (i) a first material, and (ii) a second material; wherein the first material comprises an acid and a binder; wherein the first material does not comprise nicotine; wherein the second material comprises a protonatable active; and wherein the molar ratio of the protonatable active to acid in the composition is about 4:1 or less.

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

Also provided is a non-combustible aerosol provision system comprising the consumable described herein and a non-combustible aerosol provision device.

Also provided is a method of generating an aerosol using the non-combustible aerosol provision system described herein, the method comprising heating the aerosolgenerating composition to a temperature of less than 350 °C.

In another aspect, there is provided a method of making the aerosol-generating composition described herein, the method comprising:

(a) forming the first material; and

(b) mixing the first material with the second material.

To the extent that they are combinable, features described herein in relation to one aspect of the invention are explicitly disclosed in combination with each and every other aspect.

Further features and advantages of the invention will become apparent from the following description, given by way of example only, and with reference to the accompanying figures.

Brief Description of the Figures

Figure 1 shows a section view of an example of an aerosol-generating article.

Figure 2 shows a perspective view of the article of Figure 1 .

Figure 3 shows a sectional elevation of an example of an aerosol-generating article.

Figure 4 shows a perspective view of the article of Figure 3. Figure 5 shows a perspective view of an example of a non-combustible aerosol provision system.

Figure 6 shows a section view of an example of a non-combustible aerosol provision system.

Figure 7 shows a perspective view of an example of a non-combustible aerosol provision system.

Detailed Description

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

The first material (also called an aerosol-generating material), and optionally also the second material, may be an “amorphous solid”. In some embodiments, the first material (and optionally also the second material) comprises an aerosol-generating film that is an amorphous solid. In some embodiments, the amorphous solid is a “monolithic solid”. The first material (and optionally also the second material) may be non-fibrous or fibrous. For example, the first material (and optionally also the second material) may be substantially non-fibrous. In some embodiments, the first material (and optionally also the second material) may be a dried gel.

The first material (and optionally also the second material) is a solid material that may retain some fluid, such as liquid, within it. In some embodiments the retained fluid may be water (such as water absorbed from the surroundings of the materials) or the retained fluid may be solvent (such as when the first material (and optionally also the second material) is formed from a slurry). In some embodiments, the solvent may be water.

In other embodiments, the first material (and optionally also the second material) may comprise a cellulose-based substrate, such as paper, which is coated or impregnated with the components of the material (e.g. at least an acid and a binder for the first material). As described hereinabove, the invention provides an aerosol-generating composition comprising:

(i) a first material; and

(ii) a second material.

The first material comprises an acid and a binder, and does not comprise nicotine. The second material comprises a protonatable active (such as nicotine), and the molar ratio of the protonatable active to acid in the composition is about 4:1 or less.

In some embodiments, the first material (and optionally also the second material) further comprises an aerosol-former material and/or a filler.

As discussed above, the first material comprises an acid and a binder, but does not comprise nicotine. The second material comprises a protonatable active (such as nicotine), and the molar ratio of the protonatable active to acid in the composition is about 4:1 or less. In some aspects, the second material does not comprise any acid.

The presence of an acid may modify (e.g. improve) the flavour and impact of an aerosol which is generated from any given aerosol-generating material or composition when a protonatable active (such as nicotine) is present in said aerosol-generating material or composition. For example, the perceived harshness of (or irritation caused by) the nicotine may be reduced by the presence of the acid. To achieve this effect, it has been known to include acid in aerosol-generating compositions, for example by adding acid to a slurry which is then formed into an aerosol-generating material. Alternatively or additionally, acid can be added to an aerosol-generating material or composition (including a tobacco material) after formation of the material or composition (e.g. by spraying).

However, including acid in an aerosol-generating material or composition can sometimes have a negative effect on the taste profile of the aerosol generated from said material or composition. For example, the acid can negatively impact the taste of tobacco, for example by muting or reducing the flavour characteristics of aerosol generated from tobacco or tobacco-containing aerosol-generating materials or compositions. That it, the tobacco taste intensity can be reduced by the presence of an acid. Including an acid can also reduce the taste impact of the first puff. It has now been found that the sensory attributes of an aerosol which is generated from an aerosol-generating composition comprising a protonatable active (such as nicotine) may be further improved when the acid and the protonatable active (e.g. nicotine) are present in separate materials within the composition, for example when the acid is present in a first material and the protonatable active is present in a second material. For example, the perceived hardness of or irritation caused by the aerosol may be decreased. Additionally, the impact of the first puff can be maintained.

Importantly, the perceived flavour characteristics of the aerosol (e.g. the tobacco taste intensity) may be less affected when the acid and the protonatable active are in separate materials compared to when the acid is in the same material as the protonatable active.

Thus, in the present invention the first material comprises an acid but does not comprise nicotine, and the second material comprises a protonatable active (such as nicotine). In one aspect the second material does not comprise any acid.

In one aspect the second material comprises or is tobacco, which comprises nicotine. Alternatively, the second material may be an aerosol generating material which may be formed from a slurry as described herein (i.e. like the first material but with a different composition). This second (e.g. tobacco) material can be mixed with the first material, which may be formed from a slurry as described elsewhere herein. In one aspect, one or both of the first and second materials are formed as sheets, which are then shredded and mixed or blended together.

In one embodiment the aerosol-generating composition is in the form of a shredded composition, where the first material and the second material are mixed together. Such a mixture may increase mixing of the aerosol when it is produced and thus the rate and/or degree of active protonation.

In one embodiment, the molar ratio of protonatable active to acid in the composition is about 3:1 or less, such as about 2:1 or less, or about 1 .5:1 or less.

The molar ratio of protonatable active to acid in the composition may be about 0.2:1 or more, such as about 0.25:1 or more, about 0.3:1 or more, or about 0.5:1 or more. In one embodiment, the molar ratio of protonatable active to acid in the composition is from about 0.25:1 to about 3:1 , such as from about 0.3:1 to about 2:1 or from about 0.5:1 to about 1.5:1.

In one embodiment, the molar ratio of protonatable active to acid in the composition is about 1 :1.

In some embodiments, the aerosol-generating composition may comprise from about

1 to about 99 wt% of first material, and from about 1 to about 99 wt% of second material. In other embodiments, the aerosol-generating composition may comprise from about 10 to about 90 wt.% first material and from about 10 to about 90 wt% second material. In other embodiments, the aerosol-generating composition may comprise from about 25 to about 75 wt.% first material and from about 25 to about 75 wt% second material. In other embodiments, the aerosol-generating composition may comprise from about 40 to about 60 wt.% first material and from about 40 to about 60 wt% second material.

In other embodiments, the aerosol-generating composition may comprise from about

2 to about 50 wt.% first material and from about 50 to about 98 wt% second material. In other embodiments, the aerosol-generating composition may comprise from about 5 to about 30 wt.% first material and from about 70 to about 95 wt% second material. In further embodiments, the aerosol-generating composition may comprise from about 10 to about 20 wt.% first material and from about 80 to about 90 wt% second material.

In each case, the amount of the first material and the second material will generally sum to 100% (i.e. these are the only materials present in the composition). That is, in some embodiments the aerosol-generating composition consists of (or consists essentially of) the first material and the second material, as defined herein.

In some embodiments, the first material (and optionally also the second material) may contain less than about 20 wt%, such as less than about 15 wt%, 12 wt% or 10 wt% of water calculated on a wet weight basis (WWB). For example, the first material (and optionally also the second material) may contain about 1-15 wt% of water, such as 3- 12 wt% of water (WWB). The first material (and optionally also the second material) may be a hydrogel.

Acid The first material comprises one or more acids. The acid may be an organic acid. In some embodiments, the acid may be at least one of a monoprotic acid, a diprotic acid and a triprotic acid. In some such embodiments, the acid may contain at least one carboxyl functional group. In some such embodiments, the acid may be at least one of an alpha-hydroxy acid, carboxylic acid, dicarboxylic acid, tricarboxylic acid and keto acid. In some such embodiments, the acid may be an alpha-keto acid.

In other embodiments the acid may be an inorganic acid. In some of these embodiments the acid may be a mineral acid. In some such embodiments, the acid may be at least one of sulphuric acid, hydrochloric acid, boric acid and phosphoric acid.

In some embodiments, the acid may be at least one of levulinic acid, lactic acid, benzoic acid, succinic acid, citric acid, tartaric acid, fumaric acid, acetic acid, malic acid, formic acid, sorbic acid, benzoic acid, propanoic and pyruvic acid.

In some embodiments, the acid may be at least one of levulinic acid, lactic acid, and benzoic acid.

Suitably the acid is levulinic acid. In other embodiments, the acid is lactic acid. In other embodiments, the acid is benzoic acid.

The term lactic acid is synonymous with the term 2-hydroxypropanoic acid and covers both D and L enantiomers separately or a mixture thereof. For example, the lactic acid can be a mixture (for example a racemic mixture) of D-2-hydroxypropanoic acid and 2- hydroxypropanoic acid. The term levulinic acid is synonymous with the term 4- oxopentanoic acid.

Binder

The first material (and optionally also the second material) may comprise from about 1 wt%, 3 wt%, 5 wt%, 7 wt%, or 10 wt% to about 60 wt%, 50 wt%, 40 wt%, 30 wt%, 25 wt% or 20 wt% binder (all calculated on a dry weight basis). In exemplary embodiments, the first material (and optionally also the second material) comprises about 1 to about 60 wt% binder, such as from about 3 to about 50 wt%, from about 5 to about 30 wt%, from about 5 to about 25 wt% or from about 7 to about 20 wt%. The binder used herein may comprise a hydrocolloid. In some examples, the binder may comprise 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 examples, the binder comprises one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose, pullulan, xanthan gum guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol.

In some examples, the binder comprises alginate and/or pectin, and may be combined with a setting agent (such as a calcium source) during formation of the material. In some examples, the first material (and optionally also the second material) may comprise a calcium-crosslinked alginate and/or a calcium-crosslinked pectin.

The binder may comprise one or more compounds selected from cellulosic binders, non-cellulosic binders, guar gum, acacia gum and mixtures thereof.

In some embodiments, the cellulosic binder is selected from the group consisting of: hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose (CMC), hydroxypropyl methylcellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP) and combinations thereof.

In some embodiments, the binder comprises (or is) one or more of hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose (HPMC), carboxymethylcellulose, guar gum, or acacia gum.

In some embodiments, the binder comprises (or is) carboxymethylcellulose.

In some embodiments, the binder comprises (or is) one or more non-cellulosic binder, including, but not limited to, agar, xanthan gum, gum Arabic, guar gum, locust bean gum, pectin, carrageenan, starch, alginate, and combinations thereof. In some embodiments, the binder comprises (or is) alginate and/or pectin.

Aerosol-former material The first and/or second materials may comprise an aerosol-former. In one embodiment, the first material comprises an aerosol-former material. In one embodiment, the first and second materials comprise an aerosol-former material.

The aerosol-former material may comprise one or more constituents capable of forming an aerosol. In some embodiments, the aerosol-former material comprises one or more 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, and propylene carbonate.

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

In particular embodiments, the aerosol-former material comprises glycerol in combination with propylene glycol. In particular embodiments, the aerosol-former material comprises glycerol.

The first material (and optionally also the second material) may comprise from about 1 wt% to about 60 wt% of aerosol-former material. In some embodiments, the first material (and optionally also the second material) may comprise from about 1 wt%, 10 wt%, 20 wt%, 30 wt% or 40 wt% to about 60 wt%, 55 wt%, 50 wt%, 45 wt% or 40 wt% of aerosol-former material. In particular embodiments, the first material (and optionally also the second material) comprises from about 10 to about 60 wt% or from about 20 to about 55 wt% aerosol-former material.

In some embodiments, the first material (and optionally also the second material) comprises from about 20 to about 40 wt% or from about 25 to about 35 wt% aerosolformer material, such as about 30 wt%.

In some embodiments, the first material (and optionally also the second material) comprises from about 40 to about 60 wt% or from about 45 to about 55 wt% aerosolformer material, such as about 50 wt%. Filler

The first material (and optionally also the second material) may comprise one or more fillers. Use of a filler may help to reduce tackiness of the material, for example if high levels of aerosol-former material are present.

In some embodiments, the first material (and optionally also the second material) comprises from about 1 wt%, 5 wt%, 10 wt%, 18 wt% or 20 wt% to about 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt% or 30 wt% of filler (all calculated on a dry weight basis). For example, the first material (and optionally also the second material) may comprise from about 1 to about 60 wt% filler, such as from about 1 to about 50wt%. from about 5 to about 45wt%, from about 10 to about 40wt%, from about 18 to about 35wt% or from about 20 to about 30wt%. These amounts represent the total amount of filler(s) in the material.

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

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

In some cases, the filler comprises wood pulp, MCC and/or ground cellulose.

In some cases, the filler comprises (or is) ground cellulose.

In some cases, the filler comprises (or is) wood pulp.

As would be well understood by the skilled person, microcrystalline cellulose may be formed by depolymerising cellulose by a chemical process (e.g. using an acid or enzyme). One example method for forming microcrystalline cellulose involves acid hydrolysis of cellulose, using an acid such as HCI. The cellulose produced after this treatment is crystalline. Suitable methods and conditions for forming microcrystalline cellulose are well-known in the art. In some embodiments, the first material (and optionally also the second material) does not comprise inorganic filler. In some embodiments, the aerosol-generating composition does not comprise inorganic filler.

In some embodiments, the first material (and optionally also the second material) does not comprise calcium carbonate, such as chalk. In some embodiments, the aerosolgenerating composition does not comprise calcium carbonate, such as chalk.

In particular embodiments, the first material (and optionally also the second material) comprises filler and the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood pulp, hemp fibre, cellulose or cellulose derivatives. In some embodiments, the fibrous organic filler material may be wood pulp, hemp fibre, cellulose or cellulose derivatives. In particular embodiments, the fibrous filler is wood pulp. Without wishing to be bound by theory, it is believed that including fibrous filler in an first material (and optionally also the second material) may increase the tensile strength of the material. This may be particularly advantageous in examples wherein the first material is provided as a sheet, such as when a first material sheet circumscribes a rod of second material.

Colourant

The first material (and optionally also the second material) may comprise one or more colourants. The addition of a colourant may alterthe visual appearance of the material. The presence of colourant in the first material may enhance the visual appearance of the first material and the aerosol-generating composition. By adding a colourant to the first material, the first material may be colour-matched to other components of the aerosol-generating composition (e.g. the second material) or to other components of an article comprising the aerosol-generating composition.

A variety of colourants may be used depending on the desired colour of the material. The colour of first material (and optionally also the second material) may be, for example, white, green, red, purple, yellow, orange, blue, brown or black. Other colours are also envisaged. Natural or synthetic colourants, such as natural or synthetic dyes, food-grade colourants and pharmaceutical-grade colourants may be used. In certain embodiments, the colourant is caramel, which may confer the material with a brown appearance. In such embodiments, the colour of the first material may be similar to the colour of the second material (such as tobacco material) in the aerosol-generating composition. In some embodiments, the addition of a colourant to the first material renders it visually indistinguishable from other components in the aerosol-generating composition (such as the second material).

The colourant may be incorporated during the formation of the first material and optionally also the second material (e.g. when forming a slurry comprising the components that form the material) or it may be applied to the first material (and optionally also the second material) after its formation (e.g. by spraying it onto the material).

In some embodiments, (brown) wood pulp is present as a filler, and a colourant may therefore be unnecessary.

Active

In some embodiments, the first material (and optionally also the second material) additionally comprises an active substance.

The active substance 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 caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, 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.

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

As noted herein, the active substance may comprise one or more constituents, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.

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

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

The active substance may comprise cannabidiol (CBD).

The active substance may comprise nicotine and cannabidiol (CBD).

The active substance may comprise cannabidiol (CBD) and THC (tetrahydrocannabinol).

As noted herein, the active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof. As used herein, the term "botanical" 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. Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like. Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, 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, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens.

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

In some embodiments, the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from eucalyptus, star anise, cocoa and hemp.

In some embodiments, the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from rooibos and fennel.

In some embodiments, the first material does not comprise tobacco fibers. In some embodiments, the first material does not comprise tobacco particles. In some embodiments, the first material does not comprise tobacco fibers or tobacco particles. In some embodiments, the first material does not comprise tobacco material. In some embodiments the first material is substantially free of tobacco material.

In some embodiments, the first material does not comprise an active substance.

In some embodiments, the second material does not comprise tobacco fibers. In some embodiments, the second material does not comprise tobacco particles. In some embodiments, the second material does not comprise tobacco fibers or tobacco particles. In some embodiments, the second material does not comprise tobacco material. In some embodiments the second material is substantially free of tobacco material.

In some embodiments, the second material does not comprise an active substance.

Flavour

In some embodiments, the first material (and optionally also the second material) comprises a flavour. In some cases, the first material (and optionally also the second material) may comprise from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt% or 25 wt% to about 65wt%, 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (calculated on a dry weight basis) of flavour.

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 butyl ether and a suitable cooling agent may be, but not limited to eucolyptol, WS-3.

In some embodiments, the first material does not comprise a flavour.

In some embodiments, the second material does not comprise a flavour.

Other functional materials

In some embodiments, the first material, the second material or the aerosol-generating composition may further comprise one or more other functional materials. The one or more other functional materials may comprise one or more of pH regulators, preservatives, stabilizers, and/or antioxidants.

Form of the materials

In some embodiments, the first material (and optionally also the second material) is formed as a sheet. In some cases, the first material (and optionally also the second material) may be incorporated into the non-combustible aerosol provision system or consumable in sheet form. The first material sheet may be incorporated as a planar sheet, as a gathered or bunched sheet, as a crimped sheet, or as a rolled sheet (i.e. in the form of a tube). In some such cases, the first material of these embodiments may be included in the system/consumable as a sheet, such as a sheet circumscribing a rod of second material (e.g. tobacco). For example, the first material sheet may be formed on a wrapping paper which circumscribes a second material, such as tobacco. In other embodiments, the first material may be in the form of a cellulose-based substrate, such as paper, which is coated or impregnated with the components of the first material (i.e. acid, etc.).

In other cases, the first material may be shredded and then mixed with the second material, such as cut rag tobacco. In one embodiment the aerosol-generating composition is in the form of a shredded composition, where the first material and the second material are both shredded and mixed together.

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

If the first material (and optionally also the second material) is too thick, then heating efficiency may be compromised. This adversely affects the power consumption in use. Conversely, if the first material (and optionally also the second material) is too thin, it may be difficult to manufacture and handle; a very thin material is harder to cast and may be fragile, compromising aerosol formation in use.

The thickness stipulated herein is a mean thickness for the material. In some cases, the thickness may vary by no more than 25%, 20%, 15%, 10%, 5% or 1%.

In some embodiments, the first material (and optionally also the second material) in sheet form may have sufficient tensile strength such that it can be wound onto, or unwound from, a bobbin without breakages. In some examples, the first material (and optionally also the second material) in sheet form has a tensile strength of greater than or equal to about 250 N/m.

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

Amounts of constituents of the material, such as aerosol-former material (e.g. glycerol), can be determined by solvent extraction followed by gas chromatography with a flame ionisation detector (GC-FID).

Second material

As described herein, the aerosol-generating composition further comprises a second material. As described above, the second material may comprise any of the components described above in relation to the first material, provided that the second material comprises a protonatable active (such as nicotine), and the molar ratio of the protonatable active to acid in the composition is about 4:1 or less.

In one embodiment, the second material may comprise or be a tobacco material. In these embodiments, the tobacco material does not form part of the first material. That is, it is present in the aerosol-generating composition separately to the first material.

The second material does not generally contain any acid. The second material may be free from, or substantially free from acid. For example, the second material may be free from, or substantially free from levulinic acid, lactic acid, benzoic acid, succinic acid, citric acid, tartaric acid, fumaric acid, acetic acid, malic acid, formic acid, sorbic acid, benzoic acid, propanoic and pyruvic acid. In one embodiment, the second material is free from, or substantially free from levulinic acid, lactic acid, and benzoic acid.

As used herein, the term “tobacco material” refers to any material comprising tobacco or derivatives therefore (including the second material, where the second material comprises or is a tobacco material). 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, reconstituted tobacco and/or tobacco extract. The tobacco used to produce tobacco material may be any suitable tobacco, such as single grades or blends, cut rag or whole leaf, including Virginia and/or Burley and/or Oriental. It may also be tobacco particle ‘fines’ or dust, expanded tobacco, stems, expanded stems, and other processed stem materials, such as cut rolled stems. The tobacco material may be a ground tobacco or a reconstituted tobacco material. The reconstituted tobacco material may comprise tobacco fibres, and may be formed by casting, a Fourdrinier-based paper making-type approach with back addition of tobacco extract, or by extrusion.

In some embodiments, the amount of aerosol-former material in the aerosol-generating composition is from about 5 to about 30 wt% of the aerosol-generating composition on a dry weight basis. For example, in some embodiments the aerosol-generating composition comprises aerosol-former material in an amount of from about 10 to about 20 wt%, or from about 13 to about 17 wt%. In some embodiments, the aerosolgenerating composition comprises aerosol-former material in an amount of about 15 wt%. This amount includes any aerosol-former material present in the first composition and any aerosol-former material loaded onto the second (e.g. tobacco) material.

In some embodiments, the tobacco material comprises or consists of lamina tobacco (such as cut rag tobacco), which provides desirable sensory characteristics.

In some embodiments, the tobacco material comprises a mixture of lamina tobacco and reconstituted tobacco.

In some embodiments, the tobacco material comprises reconstituted tobacco in an amount less than about 50 wt%, 30 wt%, 10 wt%, 5 wt%, or 1 wt% by dry weight of the tobacco material. In some embodiments, the tobacco material substantially does not comprise reconstituted tobacco.

The tobacco material may be present in any format, but is typically fine-cut (e.g. cut into narrow shreds). Fine-cut tobacco material may advantageously be blended with the first material to provide an aerosol-generating composition which has an even dispersion of tobacco material and first material throughout the aerosol-generating composition.

In some embodiments, the tobacco material comprises one or more of ground tobacco, tobacco fibre, cut tobacco, extruded tobacco, tobacco stem, reconstituted tobacco and/or tobacco extract. It is possible to use a relatively large amount of lamina tobacco in the aerosol-generating composition and still provide an acceptable aerosol when heated by a non-combustible aerosol provision system. Lamina tobacco typically provides superior sensory characteristics. In examples, the tobacco material comprises lamina tobacco in an amount of at least about 50 wt%, 60 wt%, 70 wt%, 80 wt%, 85 wt%, 90 wt%, or 95 wt% of the tobacco material. In particular examples, the tobacco material comprises cut tobacco in an amount of at least about 50 wt%, 60 wt%, 70 wt%, 80 wt%, 85 wt%, 90 wt%, or 95 wt% of the tobacco material.

The tobacco used to produce tobacco material may be any suitable tobacco, such as single grades or blends, cut rag or whole leaf, including Virginia and/or Burley and/or Oriental.

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

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

In some embodiments, the aerosol-generating composition consists of, or consists essentially of the first material and the second (e.g. tobacco) material.

In some embodiments, the second (e.g. tobacco) material itself comprises aerosolformer material. The second material may also comprise casings and/or flavourings, of the type which would be well-known to the skilled person. Typically, the second material comprises tobacco which is fine-cut, and aerosol-former material is loaded onto the shreds of tobacco. In examples, the second material comprises aerosolformer material in an amount of from about 1 to 10 wt% of the second material, such as about 3 to 6 wt%. The aerosol-former material defined above in relation to the first material are also suitable for use in the second material. The first material may be present in the aerosol-generating composition in any suitable form. In examples, the first material is present in sheet form. In examples, the first material is present as a shredded sheet (e.g. the aerosol-generating composition comprises shreds of first material). In examples, the first material is present as a shredded sheet and is blended with second (e.g. tobacco) material which is fine-cut and/or shredded, e.g. the first material and second material are in a similar form. Advantageously, providing both the first material and second material as shreds I fine- cut portions allows for an aerosol-generating composition blend which has an even dispersion of first material and second material throughout the aerosol-generating composition. This may also allow for increased mixing of the aerosol generated from each of the materials when it is produced, which can help to achieve a higher or faster degree of active protonation.

In examples, the first material has an area density which is from about 90 to 110% of the area density of the second material in the aerosol generating composition. That is, the first material and the second material have similar area densities. Configuring the first material and second material to have similar area densities allows for better blending of the first material and second material, typically when provided as shredded sheet. For example, first material in the form of a shredded sheet and cut rag tobacco which have similar area densities can be blended to provide a more homogenous aerosol-generating composition (e.g. better distribution of each component throughout the aerosol-generating composition).

Fine cut tobacco (such as cut rag tobacco) has a cut width, typically represented as CPI (cuts per inch), and refers to the width of a shred of tobacco. In some examples where the tobacco material is fine cut (e.g. where the tobacco material comprises cut rag tobacco) and the first material is a shredded sheet, the cut width of the first material is from about 90 to 110% of the cut width of the cut rag tobacco. That is, the first material and the second material have similar cut widths, or shred widths. Configuring the first material and second material to have similar cut widths allows for better blending of the first material and second material. For example, shredded first material sheet and cut rag tobacco which have similar cut widths can be blended to provide a more homogenous aerosol-generating composition (e.g. better distribution of each component throughout the aerosol-generating composition). The tobacco material may have a length of 1-4 cm.

Protonatable active The second material of the aerosol-generating composition comprises a protonatable active substance, such as nicotine. The protonatable active is any active (such as those listed herein) which can be protonated to form a salt form, such as by the acids listed herein. Suitable protonatable actives include nicotine and caffeine, but are not limited to these. In one aspect, the protonatable active can be protonated in the vapour phase, such that a salt of the active is formed.

In some embodiments, the second material may comprise from about 1 wt%, 2 wt%, 3 wt% , 4 wt% or 5 wt% to about 20 wt% , 18 wt% , 15 wt% , 12 wt% or 10 wt% (calculated on a dry weight basis) of protonatable active. For example, the second material may comprise from about 1 to about 20 wt% protonatable active, such as from about 2 to about 18 wt% or from about 3 to about 12 wt%.

Carrier

The aerosol-generating composition may comprise a carrier on which the first material and/or the second material is provided. The carrier functions as a support on which the material layer forms, easing manufacture. The carrier may provide tensile strength to the material layer, easing handling. In some embodiments the first material is provided on a carrier.

In some cases, the carrier may be formed from materials selected from metal foil, paper, carbon paper, greaseproof paper, ceramic, carbon allotropes such as graphite and graphene, plastic, cardboard, wood or combinations thereof. In some cases, the carrier may comprise or consist of a tobacco material, such as a sheet of reconstituted tobacco. In some cases, the carrier may be formed from materials selected from metal foil, paper, cardboard, wood or combinations thereof. In some cases, the carrier itself be a laminate structure comprising layers of materials selected from the preceding lists. In some cases, the carrier may also function as a flavour carrier. For example, the carrier may be impregnated with a flavour or with tobacco extract.

In some cases, the surface of the carrier that abuts the material may be porous. For example, in one case, the carrier comprises paper. A porous carrier such as paper has been found to be particularly suitable; the porous (e.g. paper) layer abuts the material layer and forms a strong bond. The first and/or second material may be formed by drying a slurry and, without being limited by theory, it is thought that the slurry partially impregnates the porous carrier (e.g. paper) so that the carrier is partially bound into the material. This provides a strong binding between the material and the carrier.

In some embodiments, the first and/or second material may be laminated to a carrier, such as a paper sheet.

In some embodiments, when the first and/or second material is formed from a slurry as described herein, the layer of slurry may be formed on a carrier, such as a paper sheet.

In some cases, the carrier is formed from or comprises metal foil, such as aluminium foil. A metallic carrier may allow for better conduction of thermal energy to the material. Additionally, or alternatively, a metal foil may function as a susceptor in an induction heating system. In particular embodiments, the carrier comprises a metal foil layer and a support layer, such as cardboard. In these embodiments, the metal foil layer may have a thickness of less than 20 pm, such as from about 1 pm to about 10 pm, suitably about 5 pm.

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

Consumable

In another aspect of the disclosure, there is provided a consumable for use in a noncombustible aerosol provision device, the consumable comprising the aerosolgenerating composition as defined herein.

In some embodiments, the disclosure relates to consumables comprising the aerosolgenerating composition and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.

The consumable may be used with any suitable non-combustible aerosol provision device. A consumable is an article comprising or consisting of aerosol-generating composition, part or all of which is intended to be consumed during use by a user. A consumable may comprise one or more other components, such as an aerosol-generating composition storage area, an aerosol-generating composition transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and/or an aerosol-modifying agent. A consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating composition to generate aerosol in use. The heater may, for example, comprise combustible material, a material heatable by electrical conduction, or a susceptor.

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

An aerosol-modifying agent is a substance, typically located downstream of the aerosol generation area, that is configured to modify the aerosol generated, for example by changing the taste, flavour, acidity or another characteristic of the aerosol. The aerosol-modifying agent may be provided in an aerosol-modifying agent release component, that is operable to selectively release the aerosol-modifying agent.

The aerosol-modifying agent may, for example, be an additive or a sorbent. The aerosol-modifying agent may, for example, comprise one or more of a flavourant, a colourant, water, and a carbon adsorbent. The aerosol-modifying agent may, for example, be a solid, a liquid, or a gel. The aerosol-modifying agent may be in powder, thread or granule form. The aerosol-modifying agent may be free from filtration material.

An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosol-generating composition. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating composition to heat energy, so as to release one or more volatiles from the aerosol-generating composition to form an aerosol. In some embodiments, the aerosol generator is configured to cause an aerosol to be generated from the aerosol-generating composition without heating. For example, the aerosol generator may be configured to subject the aerosol-generating composition to one or more of vibration, increased pressure, or electrostatic energy.

Non-combustible aerosol provision system

In another aspect of the disclosure, there is provided a non-combustible aerosol provision system comprising the consumable described herein and a non-combustible aerosol provision device.

According to the present disclosure, a “non-combustible” aerosol provision system is one where a constituent aerosol-generating composition 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.

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

In some embodiments, the non-combustible aerosol provision device is a heat-not- burn device.

In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating compositions, one or a plurality of which may be heated. In some embodiments, the hybrid system comprises the aerosol-generating composition described herein and an additional liquid or gel aerosol-generating composition.

In some embodiments, the non-combustible aerosol provision device is an electronic tobacco hybrid device. Typically, the non-combustible aerosol provision system may comprise a noncombustible aerosol provision device and a consumable for use with the noncombustible aerosol provision device.

In some embodiments, the non-combustible aerosol provision system, such as a noncombustible 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 composition or to a heat transfer material in proximity to the exothermic power source.

In some embodiments, the non-combustible aerosol provision system, such as a non- combustible aerosol provision device thereof, may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent.

The non-combustible aerosol provision system or device may comprise a heater configured to heat but not burn the aerosol-generating composition. The heater may be, in some cases, a thin film, electrically resistive heater. In other cases, the heater may comprise an induction heater or the like. In yet further cases, the heater may be a combustible heat source or a chemical heat source which undergoes an exothermic reaction to produce heat in use.

In some cases, the heater may heat but not burn the aerosolisable material(s) to between 120°C and 350°C in use. In some cases, the heater may heat but not burn the aerosolisable material(s) to between 140°C and 250°C in use. In some cases in use, substantially all of the aerosol-generating composition is less than about 4 mm, 3 mm, 2 mm or 1 mm from the heater. In some cases, the solid is disposed between about 0.017 mm and 2.0 mm from the heater, suitably between about 0.1 mm and 1.0 mm.

In some cases, the heater may be embedded in the aerosol-generating composition/the first material. In some such cases, the heater may be an electrically resistive heater (with exposed contacts for connection to an electrical circuit). In other such cases, the heater may be a susceptor embedded in the first composition, which is heated by induction. The non-combustible aerosol provision system may additionally comprise a cooling element and/or a filter. The cooling element, if present, may act or function to cool gaseous or aerosol components. In some cases, it may act to cool gaseous components such that they condense to form an aerosol. It may also act to space the very hot parts of the apparatus from the user. The filter, if present, may comprise any suitable filter known in the art such as a cellulose acetate plug.

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

In some cases, the non-combustible aerosol provision system may comprise an electronic tobacco hybrid device. That is, it may contain a solid aerosolisable material and a liquid aerosolisable material. The separate aerosolisable materials may be heated by separate heaters, the same heater or, in one case, a downstream aerosolisable material may be heated by a hot aerosol which is generated from the upstream aerosolisable material. An electronic tobacco hybrid device is disclosed in WO 2016/135331 A1 , which is incorporated by reference in its entirety.

The consumable may alternatively be referred to herein as a cartridge. The consumable may be adapted for use in a THP, an electronic tobacco hybrid device or another aerosol generating device. In some cases, the consumable may additionally comprise a filter and/or cooling element, as described previously. In some cases, the consumable may be circumscribed by a wrapping material such as paper.

The consumable may additionally comprise ventilation apertures. These may be provided in the sidewall of the article. In some cases, the ventilation apertures may be provided in the filter and/or cooling element. These apertures may allow cool air to be drawn into the article during use, which can mix with the heated volatilised components thereby cooling the aerosol.

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

In some cases, the ratio of the cool airto the sum of the heated volatilised components and the cool air, known as the ventilation ratio, is at least 15%. A ventilation ratio of 15% enables the heated volatilised components to be made visible by the method described above. The visibility of the heated volatilised components enables the user to identify that the volatilised components have been generated and adds to the sensory experience of the smoking experience.

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

Referring to Figures 1 and 2, there are shown a partially cut-away section view and a perspective view of an example of article consumable 101 (“article”). The article 101 is adapted for use with a device having a power source and a heater. The article 101 of this embodiment is particularly suitable for use with the device 1 shown in Figures 5 to 7, described below. In use, the article 101 may be removably inserted into the device shown in Figure 5 at an insertion point 20 of the device 1.

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

The filter assembly 105 includes three segments, a cooling segment 107, a filter segment 109 and a mouth end segment 111. The article 101 has a first end 113, also known as a mouth end or a proximal end and a second end 115, also known as a distal end. The body of aerosol-generating composition 103 is located towards the distal end 115 of the article 101. In one example, the cooling segment 107 is located adjacent the body of aerosol-generating composition 103 between the body of aerosolgenerating composition 103 and the filter segment 109, such that the cooling segment 107 is in an abutting relationship with the aerosol-generating composition 103 and the filter segment 103. In other examples, there may be a separation between the body of aerosol-generating composition 103 and the cooling segment 107 and between the body of aerosol-generating composition 103 and the filter segment 109. The filter segment 109 is located in between the cooling segment 107 and the mouth end segment 111. The mouth end segment 111 is located towards the proximal end 113 of the article 101 , adjacent the filter segment 109. In one example, the filter segment 109 is in an abutting relationship with the mouth end segment 111. In one embodiment, the total length of the filter assembly 105 is between 37 mm and 45 mm, more preferably, the total length of the filter assembly 105 is 41 mm.

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

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

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

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

In one example, the cooling segment 107 is an annular tube and is located around and defines an air gap within the cooling segment. The air gap provides a chamber for heated volatilised components generated from the body of aerosol-generating composition 103 to flow. The cooling segment 107 is hollow to provide a chamber for aerosol accumulation yet rigid enough to withstand axial compressive forces and bending moments that might arise during manufacture and whilst the article 101 is in use during insertion into the device 1 . In one example, the thickness of the wall of the cooling segment 107 is approximately 0.29mm.

The cooling segment 107 provides a physical displacement between the aerosolgenerating composition 103 and the filter segment 109. The physical displacement provided by the cooling segment 107 will provide a thermal gradient across the length of the cooling segment 107. In one example the cooling segment 107 is configured to provide a temperature differential of at least 40 degrees Celsius between a heated volatilised component entering a first end of the cooling segment 107 and a heated volatilised component exiting a second end of the cooling segment 107. In one example the cooling segment 107 is configured to provide a temperature differential of at least 60 degrees Celsius between a heated volatilised component entering a first end of the cooling segment 107 and a heated volatilised component exiting a second end of the cooling segment 107. This temperature differential across the length of the cooling element 107 protects the temperature sensitive filter segment 109 from the high temperatures of the aerosol-generating composition 103 when it is heated by the device 1. If the physical displacement was not provided between the filter segment 109 and the body of aerosol-generating composition 103 and the heating elements of the device 1 , then the temperature sensitive filter segment may 109 become damaged in use, so it would not perform its required functions as effectively.

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

The cooling segment 107 is made of paper, which means that it is comprised of a material that does not generate compounds of concern, for example, toxic compounds when in use adjacent to the heater of the device 1. In one example, the cooling segment 107 is manufactured from a spirally wound paper tube which provides a hollow internal chamber yet maintains mechanical rigidity. Spirally wound paper tubes are able to meet the tight dimensional accuracy requirements of high-speed manufacturing processes with respect to tube length, outer diameter, roundness and straightness.

In another example, the cooling segment 107 is a recess created from stiff plug wrap or tipping paper. The stiff plug wrap or tipping paper is manufactured to have a rigidity that is sufficient to withstand the axial compressive forces and bending moments that might arise during manufacture and whilst the article 101 is in use during insertion into the device 1 .

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

In some embodiments, a capsule (not illustrated) may be provided in filter segment 109. It may be disposed substantially centrally in the filter segment 109, both across the filter segment 109 diameter and along the filter segment 109 length. In other cases, it may be offset in one or more dimension. The capsule may in some cases, where present, contain a volatile component such as a flavour or aerosol-former material.

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

In one example, the filter segment 109 is made of a 8Y15 grade of filter tow material, which provides a filtration effect on the heated volatilised material, whilst also reducing the size of condensed aerosol droplets which result from the heated volatilised material.

The presence of the filter segment 109 provides an insulating effect by providing further cooling to the heated volatilised components that exit the cooling segment 107. This further cooling effect reduces the contact temperature of the user’s lips on the surface of the filter segment 109.

In one example, the filter segment 109 is between 6mm to 10mm in length, suitably 8mm.

The mouth end segment 111 is an annular tube and is located around and defines an air gap within the mouth end segment 111. The air gap provides a chamber for heated volatilised components that flow from the filter segment 109. The mouth end segment 111 is hollow to provide a chamber for aerosol accumulation yet rigid enough to withstand axial compressive forces and bending moments that might arise during manufacture and whilst the article is in use during insertion into the device 1. In one example, the thickness of the wall of the mouth end segment 111 is approximately 0.29mm. In one example, the length of the mouth end segment 111 is between 6mm to 10mm, suitably 8mm.

The mouth end segment 111 may be manufactured from a spirally wound paper tube which provides a hollow internal chamber yet maintains critical mechanical rigidity. Spirally wound paper tubes are able to meet the tight dimensional accuracy requirements of high-speed manufacturing processes with respect to tube length, outer diameter, roundness and straightness.

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

It should be appreciated that, in one example, the mouth end segment 111 and the cooling segment 107 may be formed of a single tube and the filter segment 109 is located within that tube separating the mouth end segment 111 and the cooling segment 107.

Referring to Figures 3 and 4, there are shown a partially cut-away section and perspective views of an example of an article 301. The reference signs shown in Figures 3 and 4 are equivalent to the reference signs shown in Figures 1 and 2, but with an increment of 200.

In the example of the article 301 shown in Figures 3 and 4, a ventilation region 317 is provided in the article 301 to enable air to flow into the interior of the article 301 from the exterior of the article 301 . In one example the ventilation region 317 takes the form of one or more ventilation holes 317 formed through the outer layer of the article 301 . The ventilation holes may be located in the cooling segment 307 to aid with the cooling of the article 301. In one example, the ventilation region 317 comprises one or more rows of holes, and preferably, each row of holes is arranged circumferentially around the article 301 in a cross-section that is substantially perpendicular to a longitudinal axis of the article 301. In one example, there are between one to four rows of ventilation holes to provide ventilation for the article 301. Each row of ventilation holes may have between 12 to 36 ventilation holes 317. The ventilation holes 317 may, for example, be between 100 to 500pm in diameter. In one example, an axial separation between rows of ventilation holes 317 is between 0.25mm and 0.75mm, suitably 0.5mm.

In one example, the ventilation holes 317 are of uniform size. In another example, the ventilation holes 317 vary in size. The ventilation holes can be made using any suitable technique, for example, one or more of the following techniques: laser technology, mechanical perforation of the cooling segment 307 or pre-perforation of the cooling segment 307 before it is formed into the article 301. The ventilation holes 317 are positioned so as to provide effective cooling to the article 301 .

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

Providing the rows of ventilation holes between 17mm and 20mm from the proximal end 313 of the article 301 enables the ventilation holes 317 to be located outside of the device 1 , when the article 301 is fully inserted in the device 1 , as can be seen in Figures 6 and 7. By locating the ventilation holes outside of the device, non-heated air is able to enter the article 301 through the ventilation holes from outside the device 1 to aid with the cooling of the article 301.

The length of the cooling segment 307 is such that the cooling segment 307 will be partially inserted into the device 1 , when the article 301 is fully inserted into the device 1 . The length of the cooling segment 307 provides a first function of providing a physical gap between the heater arrangement of the device 1 and the heat sensitive filter arrangement 309, and a second function of enabling the ventilation holes 317 to be located in the cooling segment, whilst also being located outside of the device 1 , when the article 301 is fully inserted into the device 1 . As can be seen from Figures 6 and 7, the majority of the cooling element 307 is located within the device 1 . However, there is a portion of the cooling element 307 that extends out of the device 1. It is in this portion of the cooling element 307 that extends out of the device 1 in which the ventilation holes 317 are located. Referring now to Figures 5 to 7 in more detail, there is shown an example of a device 1 arranged to heat aerosol-generating composition to volatilise at least one component of said aerosol-generating composition, typically to form an aerosol which can be inhaled. The device 1 is a heating device which releases compounds by heating, but not burning, the aerosol-generating composition.

A first end 3 is sometimes referred to herein as the mouth or proximal end 3 of the device 1 and a second end 5 is sometimes referred to herein as the distal end 5 of the device 1 . The device 1 has an on/off button 7 to allow the device 1 as a whole to be switched on and off as desired by a user.

The device 1 comprises a housing 9 for locating and protecting various internal components of the device 1. In the example shown, the housing 9 comprises a unibody sleeve 11 that encompasses the perimeter of the device 1 , capped with a top panel 17 which defines generally the ‘top’ of the device 1 and a bottom panel 19 which defines generally the ‘bottom’ of the device 1. In another example the housing comprises a front panel, a rear panel and a pair of opposite side panels in addition to the top panel 17 and the bottom panel 19.

The top panel 17 and/or the bottom panel 19 may be removably fixed to the uni-body sleeve 11 , to permit easy access to the interior of the device 1 , or may be “permanently” fixed to the uni-body sleeve 11 , for example to deter a user from accessing the interior of the device 1. In an example, the panels 17 and 19 are made of a plastics material, including for example glass-filled nylon formed by injection moulding, and the uni-body sleeve 11 is made of aluminium, though other materials and other manufacturing processes may be used.

The top panel 17 of the device 1 has an opening 20 at the mouth end 3 of the device 1 through which, in use, the article 101 , 301 including the aerosol-generating composition may be inserted into the device 1 and removed from the device 1 by a user.

The housing 9 has located or fixed therein a heater arrangement 23, control circuitry 25 and a power source 27. In this example, the heater arrangement 23, the control circuitry 25 and the power source 27 are laterally adjacent (that is, adjacent when viewed from an end), with the control circuitry 25 being located generally between the heater arrangement 23 and the power source 27, though other locations are possible.

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

The power source 27 may be for example a battery, which may be a rechargeable battery or a non-rechargeable battery. Examples of suitable batteries include for example a lithium-ion battery, a nickel battery (such as a nickel-cadmium battery), an alkaline battery and/ or the like. The battery 27 is electrically coupled to the heater arrangement 23 to supply electrical power when required and under control of the control circuitry 25 to heat the aerosol-generating composition in the article (as discussed, to volatilise the aerosol-generating composition without causing the aerosol-generating composition to burn).

An advantage of locating the power source 27 laterally adjacent to the heater arrangement 23 is that a physically large power source 25 may be used without causing the device 1 as a whole to be unduly lengthy. As will be understood, in general a physically large power source 25 has a higher capacity (that is, the total electrical energy that can be supplied, often measured in Amp-hours or the like) and thus the battery life for the device 1 can be longer.

In one example, the heater arrangement 23 is generally in the form of a hollow cylindrical tube, having a hollow interior heating chamber 29 into which the article 101 , 301 comprising the aerosol-generating composition is inserted for heating in use. Different arrangements for the heater arrangement 23 are possible. For example, the heater arrangement 23 may comprise a single heating element or may be formed of plural heating elements aligned along the longitudinal axis of the heater arrangement 23. The or each heating element may be annular or tubular, or at least part-annular or part-tubular around its circumference. In an example, the or each heating element may be a thin film heater. In another example, the or each heating element may be made of a ceramics material. Examples of suitable ceramics materials include alumina and aluminium nitride and silicon nitride ceramics, which may be laminated and sintered. Other heating arrangements are possible, including for example inductive heating, infrared heater elements, which heat by emitting infrared radiation, or resistive heating elements formed by for example a resistive electrical winding. In one particular example, the heater arrangement 23 is supported by a stainless steel support tube and comprises a polyimide heating element. The heater arrangement 23 is dimensioned so that substantially the whole of the body of aerosol-generating composition 103, 303 of the article 101 , 301 is inserted into the heater arrangement 23 when the article 101 , 301 is inserted into the device 1 .

The or each heating element may be arranged so that selected zones of the aerosolgenerating composition can be independently heated, for example in turn (over time, as discussed above) or together (simultaneously) as desired.

The heater arrangement 23 in this example is surrounded along at least part of its length by a thermal insulator 31. The insulator 31 helps to reduce heat passing from the heater arrangement 23 to the exterior of the device 1 . This helps to keep down the power requirements for the heater arrangement 23 as it reduces heat losses generally. The insulator 31 also helps to keep the exterior of the device 1 cool during operation of the heater arrangement 23. In one example, the insulator 31 may be a double-walled sleeve which provides a low pressure region between the two walls of the sleeve. That is, the insulator 31 may be for example a “vacuum” tube, i.e. a tube that has been at least partially evacuated so as to minimise heat transfer by conduction and/or convection. Other arrangements for the insulator 31 are possible, including using heat insulating materials, including for example a suitable foam-type material, in addition to or instead of a double-walled sleeve.

The housing 9 may further comprises various internal support structures 37 for supporting all internal components, as well as the heating arrangement 23.

The device 1 further comprises a collar 33 which extends around and projects from the opening 20 into the interior of the housing 9 and a generally tubular chamber 35 which is located between the collar 33 and one end of the vacuum sleeve 31. The chamber 35 further comprises a cooling structure 35f, which in this example, comprises a plurality of cooling fins 35f spaced apart along the outer surface of the chamber 35, and each arranged circumferentially around outer surface of the chamber 35. There is an air gap 36 between the hollow chamber 35 and the article 101 , 301 when it is inserted in the device 1 over at least part of the length of the hollow chamber 35. The air gap 36 is around all of the circumference of the article 101 , 301 over at least part of the cooling segment 307. The collar 33 comprises a plurality of ridges 60 arranged circumferentially around the periphery of the opening 20 and which project into the opening 20. The ridges 60 take up space within the opening 20 such that the open span of the opening 20 at the locations of the ridges 60 is less than the open span of the opening 20 at the locations without the ridges 60. The ridges 60 are configured to engage with an article 101 , 301 inserted into the device to assist in securing it within the device 1. Open spaces (not shown in the Figures) defined by adjacent pairs of ridges 60 and the article 101 , 301 form ventilation paths around the exterior of the article 101 , 301. These ventilation paths allow hot vapours that have escaped from the article 101 , 301 to exit the device 1 and allow cooling air to flow into the device 1 around the article 101 , 301 in the air gap 36.

In operation, the article 101 , 301 is removably inserted into an insertion point 20 of the device 1 , as shown in Figures 5 to 7. Referring particularly to Figure 6, in one example, the body of aerosol-generating composition 103, 303, which is located towards the distal end 115, 315 of the article 101 , 301 , is entirely received within the heater arrangement 23 of the device 1. The proximal end 113, 313 of the article 101 , 301 extends from the device 1 and acts as a mouthpiece assembly for a user.

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

The primary flow path for the heated volatilised components from the body of aerosolgenerating composition 103, 303 is axially through the article 101 , 301 , through the chamber inside the cooling segment 107, 307, through the filter segment 109, 309, through the mouth end segment 111 , 313 to the user. In one example, the temperature of the heated volatilised components that are generated from the body of aerosolgenerating composition is between 60°C and 250°C, which may be above the acceptable inhalation temperature for a user. As the heated volatilised component travels through the cooling segment 107, 307, it will cool and some volatilised components will condense on the inner surface of the cooling segment 107, 307.

In the examples of the article 301 shown in Figures 3 and 4, cool air will be able to enter the cooling segment 307 via the ventilation holes 317 formed in the cooling segment 307. This cool air will mix with the heated volatilised components to provide additional cooling to the heated volatilised components.

Method of producing aerosol-generating composition

Another aspect of the invention provides a method of making an aerosol-generating composition as described herein. The method may comprise:

(a) forming the first material; and

(b) mixing the first material with the second material.

In some embodiments, step (a) comprises (i) forming a mixture or slurry comprising components of the first material and a solvent (typically water). The slurry or mixture formed in step (i) therefore comprises a solvent, an acid, a binder, and other optional components of the first material as listed above, such as an aerosol-generating agent, a filler, and/or a flavour. The mixture or slurry may comprise these components on a dry weight basis in any of the proportions given herein in relation to the composition of the first material. The slurry or mixture will not comprise nicotine.

The disclosures herein relating to constituents of the first material apply equally to the slurry. The slurry may comprise these constituents in any of the proportions given herein in relation to the composition of the first material.

Step (a) may further comprise (ii) forming a layer of the mixture or slurry.

When the first material comprises alginate and/or pectin, the slurry may further comprise a setting agent and/or a setting agent may be applied to the slurry. In this case, the method may further comprise a step of setting the slurry. In some examples, forming the layer of the slurry and/or setting the slurry and/or drying the slurry, at least partially, occur simultaneously (for example, during electrospraying). In some examples, the steps of forming the layer of the slurry, setting the slurry with any setting agent and drying the slurry occur sequentially, in that order.

Forming a layer of the slurry typically comprises spraying, casting or extruding the slurry. In examples, the slurry layer is formed by casting the slurry.

In some examples, the slurry is applied to a support. The layer may be formed on a support. Step (a) may further comprise (iii) drying the layer of the mixture or slurry to form the first material.

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

In examples, the drying (iii) reduces the cast material thickness by at least 80%, suitably 85% or 87%. For instance, if the slurry is cast at a thickness of 2 mm, the resulting dried first material may have a thickness of 0.2 mm.

In embodiments, the dried first material forms a sheet or layer with a thickness of about 0.015 mm to about 1 .0 mm. Suitably, the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm, for example 0.05-0.3 or 0.15-0.3 mm. A material having a thickness of 0.2 mm may be particularly suitable.

In other embodiments, step (a) comprises coating or impregnating a cellulose substrate (such as paper) with components of the first material, which are optionally first mixed with a solvent such as water.

Step (b) of the method of the invention comprises mixing the first material formed in step (a) with a second material, as described herein.

The method may further comprise shredding the first material before mixing the first material with the second material.

In some embodiments, the method further comprises forming the second material, using the same process as described above in relation to the first material. When forming the second material the slurry or mixture will comprises a solvent, a protonatable active (such as nicotine), and other optional components of the second material as listed above, such as an aerosol-generating agent, a binder, a filler, and/or a flavour. The second material may be formed before, after or consecutively with the first material. In some cases, the aerosol-generating composition may comprise aerosol-former material in an amount of about 5 to about 30 wt% of the aerosol-generating composition on a dry weight basis.

The method of the invention may comprise providing the first material and combining the first material and a tobacco material to provide an aerosol-generating composition (i.e. where the second material is tobacco material).

The method typically comprises providing a first material as described hereinabove, providing tobacco material as described hereinabove, and combining the first material and tobacco material, typically in a ratio such that there is provided an aerosolgenerating composition having an aerosol-former material content of from about 5 to 30 wt% of the aerosol-generating composition.

In examples, the first material (and optionally also the second material) is provided as a shredded sheet. In particular examples, the providing the first material comprises shredding a sheet of the first material to provide the first material as a shredded sheet. In examples, the second (e.g. tobacco) material is fine-cut, and the combining the first material and second material comprises blending the shredded sheet of first material with the fine-cut second material.

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

Examples

Compositions were formed as set out below, and the taste attributes of aerosol generated from the sample compositions were then measured by 8 trained panellists, with the results set out in Table 1 .

Composition 1 comprised no first material, and a second material comprising 80 wt% reconstituted tobacco and 20 wt% lamina tobacco. Levulinic acid was sprayed onto the second material. The molar ratio of protonatable active (nicotine) to acid in the composition was 1 :1.

A first material was formed comprising 9 wt% levulinic acid, 7 wt% CMC, 7 wt% wood pulp, 27 wt% ground cellulose and 50 wt% glycerol. The first material was formed by forming and then drying a slurry comprising water, levulinic acid, CMC, wood pulp, ground cellulose and glycerol.

The first material was mixed with a second material comprising 80 wt% reconstituted tobacco and 20 wt% lamina tobacco (i.e. the same second material as Example 1) in a weight ratio of 15 wt% first material and 85 wt.% second material. No acid was applied to the second material. The molar ratio of protonatable active (nicotine) to acid in the composition was 1 :1.

A first material was formed comprising 7 wt% CMC, 7 wt% wood pulp, 36 wt% ground cellulose and 50 wt% glycerol. The first material was formed by forming and then drying a slurry comprising water, levulinic acid, CMC, wood pulp, ground cellulose and glycerol.

The first material was mixed with a second material comprising lamina tobacco in a weight ratio of 15 wt% first material and 85 wt.% second material. Levulinic acid was sprayed onto the tobacco prior to the mixing. The molar ratio of protonatable active (nicotine) to acid in the composition was 1 :1.

The first material was mixed with a second material comprising lamina tobacco in a weight ratio of 15 wt% first material and 85 wt.% second material.. No acid was applied to the second material. The molar ratio of protonatable active (nicotine) to acid in the composition was 1 :1. Table 1 - Taste attributes

The above attributes were measured relative to a control, with the control for each example being the corresponding composition but with no acid added (where acid was in the first material this was replaced with ground cellulose). For each attribute it was determined by the trained panellists whether the attribute was lower or higher than the corresponding control. For example, where a taste attribute was measured as being “lower”, it can be said that the addition of acid lowered the relevant attribute compared to the same example without any acid.

It is desirable that the addition of an acid reduces irritation which is caused by nicotine in the aerosol, but does not affect the taste profile of the tobacco. In this way it is possible to create an aerosol which is perceived as being less irritating but still having the same overall taste as aerosol generated from tobacco.

As shown by the results set out above, including an acid results in the lowering of overall irritation. However, adding an acid directly to the second material (which was achieved in Comparative Examples 1 and 3 by spraying the tobacco) also resulted in an undesirable change in the taste profile of the aerosol, in particular by reducing the impact of the first puff. In contrast, by adding the acid to the first material (as in Examples 2 and 4), overall irritation could be reduced without negatively impacting the overall taste of the aerosol, and in particular the impact of the first puff. The impact of the first puff (along with some irritation) can be particularly important where a consumer wants a cue for nicotine. It is therefore generally undesirable to reduce the impact and even the irritation of the first puff. However, overall it is desired to decrease irritation across a users session.

Claims

Claims:

1 . An aerosol-generating composition comprising: (i) a first material which comprises an acid and a binder, but does not comprise nicotine; and (ii) a second material which comprises a protonatable active; wherein the molar ratio of protonatable active to acid in the composition is about 4:1 or less.

2. The aerosol-generating composition of claim 1 , wherein the protonatable active is nicotine.

3. The aerosol-generating composition of any proceeding claim, wherein the first material is in the form of a shredded sheet.

4. The aerosol-generating composition of any proceeding claim, wherein the second material comprises tobacco.

5. The aerosol-generating composition of claim 4, wherein the tobacco comprises one or more of cut rag tobacco, lamina tobacco and reconstituted tobacco.

6. The aerosol-generating composition of any proceeding claim, wherein the molar ratio of protonatable active to acid in the composition is about 3:1 or less, about 2:1 or less, or about 1 .5:1 or less.

7. The aerosol-generating composition of any proceeding claim, wherein the molar ratio of protonatable active to acid in the composition is about 0.3:1 or more, or about 0.5:1 or more.

8. The aerosol-generating composition of any proceeding claim, wherein the molar ratio of protonatable active to acid in the composition is about 1 :1.

9. The aerosol-generating composition of any proceeding claim, wherein the first material comprises from about 1 to about 20 wt% acid, such as from about 2 to about 10 wt% acid.

10. The aerosol-generating composition of any proceeding claim, wherein the acid is succinic acid, lactic acid, benzoic acid, citric acid, tartaric acid, fumaric acid, levulinic acid, acetic acid, malic acid, formic acid, sorbic acid, benzoic acid, propanoic acid, pyruvic acid, or a combination thereof.

11 . The aerosol-generating composition of any proceeding claim, wherein the acid is levulinic acid, lactic acid, benzoic acid, or a combination thereof.

12. The aerosol-generating composition of any proceeding claim, wherein the acid is levulinic acid or lactic acid, such as levulinic acid.

13. The aerosol-generating composition of any proceeding claim, wherein the binder comprises one or more compounds selected from the group comprising alginates, cellulose derivatives, gums, silica or silicon compounds, clays and combinations thereof.

14. The aerosol-generating composition of any proceeding claim, wherein the binder comprises alginate and/or carboxymethyl cellulose.

15. The aerosol-generating composition of any proceeding claim, wherein the first material further comprises an aerosol-former material.

16. The aerosol-generating composition of claim 15, wherein the aerosol-former material comprises one or more 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, and propylene carbonate

17. The aerosol-generating composition of claim 15 or 16, wherein the first material comprises from about 1 to about 60 wt% of aerosol-former material, or from about 10 to about 60 wt% of aerosol-former material.

18. The aerosol-generating composition of any proceeding claim, wherein the first material further comprises a filler.

19. The aerosol-generating composition of any proceeding claim, wherein the first material does not comprise tobacco fibers or particles, optionally wherein the first material does not comprise tobacco.

20. A consumable for use in a non-combustible aerosol provision device, the consumable comprising the aerosol-generating composition of any preceding claim.

21 . A non-combustible aerosol provision system comprising the consumable of claim 20 and a non-combustible aerosol provision device, the non-combustible aerosol provision device comprising an aerosol-generation device arranged to generate aerosol from the consumable when the consumable is used with the non- combustible aerosol provision device.

22. A method of forming the aerosol-generating composition of any of claims 1- 19, the method comprising: forming the first material, and mixing the first material with the second material, optionally wherein the method further comprises shredding the first material before mixing the first material with the second material.

23. The method of claim 22, wherein the first material is formed by

(i) forming a slurry comprising an acid, a binder, a solvent and any other components of the first material or precursors thereof;

(ii) forming a layer of the slurry; and

(iii) drying to form the first material, optionally wherein the solvent is water.

24. The method of claim 23, wherein the solvent is water.