WO2025186587A1

WO2025186587A1 - An aerosol generating material

Info

Publication number: WO2025186587A1
Application number: PCT/GB2025/050478
Authority: WO
Inventors: Louise ADAMS; Gilbert AYINA
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2024-03-08
Filing date: 2025-03-10
Publication date: 2025-09-12
Anticipated expiration: 2026-09-08
Also published as: WO2025186587A8; EP4613114A1

Abstract

There is provided an aerosol generating material comprising: a first fibrous material comprising a tobacco material, and a second fibrous material comprising a non-tobacco botanical material, wherein the aerosol generating material comprises the second fibrous material in an amount of greater than about 50% by weight of the aerosol generating material.

Description

An Aerosol Generating Material

Technical Field

The present disclosure relates to an aerosol generating material comprising a first and second fibrous material, non-combustible consumables comprising the aerosol generating material, and non-combustible aerosol provision systems comprising the aerosol generating material.

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

According to a first aspect of the invention, there is provided an aerosol generating material comprising a first fibrous material comprising a tobacco material, and a second fibrous material comprising a non-tobacco botanical material, wherein the aerosol generating material comprises the second fibrous material in an amount of greater than about 50% by weight of the aerosol generating material.

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

According to a third aspect of the invention, there is provided a delivery system comprising an aerosol generating material according to the first aspect, or the aerosol generating rod according to the second aspect of the invention. Description of Drawings

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

Figure 1 is a cross-sectional view of an article comprising an aerosol generating material.

Figure 2 is a cross-sectional view of an article comprising an aerosol generating material. Figure 3 is a cross-sectional view of an article comprising an aerosol generating material.

Figure 4 is a cross-sectional view of an article comprising an aerosol generating material.

Detailed Description

Aerosol generating materials comprise aerosolisable components. In use, the aerosol generating material produces an aerosol, for example a suspension of liquid droplets or particulates in a gas. The aerosol comprises nicotine as well as other components generated by the aerosol generating material. In use, the user inhales the aerosol. As such, it is important that the aerosol generating material produces an aerosol that delivers an appropriate user experience and satisfaction.

It has been found that certain tobacco-based aerosol generating materials produce an aerosol which has distinct/different flavour and/or sensory profiles when compared to traditional cigarettes. Some of these aerosol generating materials produce an aerosol which may be less favoured by consumers.

It has been found that when a non-tobacco botanical material is combined with a tobacco material, the flavour and/or sensory profile of an aerosol generating material can be improved. In particular, when a non-tobacco botanical material is included in an aerosol generating material in an amount greater than 50%, by weight, a particularly favourable flavour profile can be achieved. In addition, it has been found that non-tobacco botanical materials behave as particularly effective flavour carriers. Therefore, utilising an aerosol generating material as set out herein, in addition to flavours and/or sensates, enables control of the flavour profile. As used herein, the term "delivery system" is intended to encompass systems that deliver a substance to a user, and includes: combustible aerosol provision systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for roll-your-own or for make-your-own cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable material); non-combustible aerosol provision systems that release compounds from an aerosol-generating material without combusting the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials; and aerosol-free delivery systems, such as lozenges, gums, patches, articles comprising inhalable powders, and smokeless tobacco products such as snus and snuff, which deliver a material to a user without forming an aerosol.

According to the present disclosure, a "combustible" aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is combusted or burned during use in order to facilitate delivery of at least one substance to a user.

In some embodiments, the delivery system is a combustible aerosol provision system, such as a system selected from the group consisting of a cigarette, a cigarillo and a cigar.

In some embodiments, the disclosure relates to a component for use in a combustible aerosol provision system, such as a filter, a filter rod, a filter segment, a tobacco rod, a spill, an aerosol-modifying agent release component such as a capsule, a thread, or a bead, or a paper such as a plug wrap, a tipping paper or a cigarette paper.

According to the present disclosure, a "non-combustible" aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery 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 electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END).

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

Typically, the non-combustible aerosol provision system may comprise a noncombustible aerosol provision device, also referred to herein as an aerosol generation device, and a consumable for use with the non-combustible aerosol provision system.

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

In some embodiments, it is envisaged that consumables which themselves comprise a means for powering an aerosol generating component may themselves form the non-combustible aerosol provision system.

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

In some embodiments, the non-combustible aerosol provision system 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.

In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol-modifying agent. In some embodiments, the substance to be delivered comprises an active substance. The active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropics, psychoactives. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, 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 is a legally permissible recreational drug.

In some embodiments, the active substance comprises nicotine, such as a nicotine salt or free base nicotine. 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 aerosol generating material comprises a cannabinoid selected from the list consisting of cannabigerol (CBG), cannabichromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol (CBN), cannabinodiol (CBDL), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethylether (CBGM), cannabinerolic acid, cannabidiolic acid (CBDA), cannabinol propyl variant (CBNV), cannbitriol (CBO), tetrahydrocannabinolic acid (THCA), and tetrahydrocannabivarinic acid (THCV A), and mixtures thereof. The active substance may be CBD or a derivative 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 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, Memtha 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 nontobacco botanical is selected from eucalyptus, cocoa and hemp. In some embodiments, the active substance comprises or is derived from one or more non-tobacco botanicals or constituents, derivatives or extracts thereof and the non-tobacco botanical is selected from star anise, rooibos, mint, and fennel. An aerosol is a suspension of particles of liquid, solid, or both, within a gas.

In some embodiments, the second fibrous material comprises rooibos. In some embodiments, the non-tobacco botanical material comprises rooibos.

In some embodiments, the substance to be delivered comprises a 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, such as terpenes.

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

In some embodiments, the flavour comprises menthol, spearmint and/or peppermint. In some embodiments, the flavour comprises flavour components of berry fruits, citrus fruits, and/or tropical fruits. In some embodiments, the flavour may comprise cucumber, blueberry, citrus fruits, pineapple, strawberry, and/or redberry.

In some embodiments, the flavour added to an aerosol generating material may be selected to enhance the underlying aroma properties of the aerosol generating material. For example, as described herein, a non-tobacco botanical material may be selected as a major component of the fibrous material. In such instances, the non-tobacco botanical material may produce a particularly neutral aroma profile, for example when rooibos, fennel, star anise, and/or mint are utilised in the aerosol generating material, it is noted that the resulting aerosol is relatively neutral in aroma. When one, or more, of rooibos, fennel, star anise, and/or mint are used, the aroma produced may be enhanced when paired with a flavour such as menthol, spearmint, peppermint; berry fruits, citrus fruits, and/or tropical fruits, or any combination of these flavours. The presence of such neutral, or subtle, aromas also do not diminish the flavour, or aroma, of the tobacco material. It has been found that certain known aerosol generating materials interact with the natural aroma/flavour of tobacco material in a negative/undesirable manner. The present aerosol generating material circumvents this negativity associated with certain known aerosol generating materials.

An aerosol generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way.

Aerosol generating materials may, for example, be in the form of a solid, liquid or semi-solid (such as a gel) which may or may not contain an active substance and/or flavourants. The aerosol-generating material may comprise one or more active substances and/or flavours, one or more aerosol-former materials, and optionally one or more other functional material.

The aerosol generating material may comprise, or be, a collection of individual sheets of material. For example, the aerosol generating material may comprise a first sheet comprising a first fibrous material comprising a tobacco material, and a second sheet comprising a second fibrous material comprising a nontobacco botanical material. The aerosol generating material may be described as being a blend of a first fibrous material comprising a tobacco material and a second fibrous material comprising a non-tobacco botanical material.

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

The sheet or shredded sheet comprises a first surface and a second surface opposite the first surface. The dimensions of the first and second surfaces are congruent. The first and second surfaces of the sheet or shredded sheet may have any shape. For example, the first and second surfaces may be square, rectangular, oblong or circular. Irregular shapes are also envisaged. The first and/or second surfaces of the sheet or shredded sheet may be relatively uniform (e.g. they may be relatively smooth) or they may be uneven or irregular. For example, the first and/or second surfaces of the sheet may be textured or patterned to define a relatively coarse surface. In some embodiments, the first and/or second surfaces are relatively rough. The smoothness of the first and second surfaces may be influenced by a number of factors, such as the area density of the sheet or shredded sheet, the nature of the components that make up the aerosolisable material or whether the surfaces of the material have been manipulated, for example embossed, scored or otherwise altered to confer them with a pattern or texture.

The shredded sheet may comprise one or more strands or strips of the aerosolisable material. In some embodiments, the shredded sheet comprises a plurality (e.g. two or more) strands or strips of the aerosolisable material. Where the shredded sheet comprises a plurality of strands or strips of material, the dimensions of each strand or strip may vary between different strands or strips.

For example, the shredded sheet may comprise a first population of strands or strips and a second population of strands or strips, wherein the dimensions of the strands or strips of the first population are different to the dimensions of the strands or strips of the second population. In other words, the plurality of strands or strips may comprise a first population of strands or strips having a first aspect ratio and a second population of strands or strips having a second aspect ratio that is different to the first aspect ratio.

A first dimension, or cut width, of the strands or strips of aerosolisable material is between 0.9 mm and 1.5 mm. When strands or strips of aerosolisable material have a cut width of below 0.9 mm are incorporated into an article for use in a noncombustible aerosol provision system, the pressure drop across the article may be increased to a level that renders the article unsuitable for use in a non-combustible aerosol-provision device. However, if the strands or strips have a cut width above 2 mm (e.g. greater than 2 mm), then it may be challenging to insert the strands or strips of aerosolisable material into the article during its manufacture. In a preferred embodiment, the cut width of the strands or strips of aerosolisable material is between about 1 mm and 1.5 mm. A consumable is an article comprising or consisting of aerosol-generating material, part or all of which is intended to be consumed during use by a user. In some embodiments, the consumable for use with a non-combustible aerosol provision device may comprise one or more other components, such as, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, 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 material 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.

In some embodiments, the aerosol generating material, when present in a consumable, has a density of about 0.1 g/cm³ to about 0.7 g/cm³. For example, the density of the aerosol generating material in a consumable may be from about 0.15 g/cm³ to about 0.65 g/cm³ such as from about 0.15 g/cm³ to about 0.60 g/cm³, such as about 0.15 g/cm³ to about 0.55 g/cm³, such as about 0.15 g/cm³ to about 0.50 g/cm³, such as about 0.15 g/cm³ to about 0.45 g/cm³, such as about 0.20 g/cm³ to about 0.45 g/cm³, such as about 0.20 g/cm³ to about 0.40 g/cm³.

As shown in Figure 1, the mouthpiece 2 of the article 1 comprises an upstream end closest to the aerosol generating material 5 and a downstream end distal from the aerosol generating material 5. The article 1 may further comprise a secondary filter segment 3, which may include filtration material such as a carbonaceous material, or may comprise a flavour modifier, such as a flavoured capsule, as well known in the art. The article 1 may comprise a region 4 designed to reduce the temperature of an aerosol generated from the aerosol generating material 5. Methods of reducing the temperature of an aerosol in an article are well known in the art, and include elements such as a heat displacement collar/section, a hollow tube, or any other known feature. The article 1 has an aerosol generating material 5 comprising a blend of a first fibrous material comprising a tobacco material and a second fibrous material comprising a non-tobacco botanical material, as set out herein.

Figure 2 illustrates an alternative article 1, comprising separate, distinct, aerosol generating materials. For example, aerosol generating material 5 comprises a first fibrous material comprising a tobacco material and aerosol generating material 6 comprises a second fibrous material comprising a nontobacco botanical material. Figures 3 and 4, illustrate further alternative articles 1, wherein the first fibrous material comprising a tobacco material 5 and the second fibrous material comprising a non-botanical botanical material 6 extend along the length of the aerosol generating portion of the article 1 in different arrangements.

By modifying the arrangement of the first fibrous material and the second fibrous material within a consumable, a user may be able to perceive different experiences.

A fibrous material comprising a non-tobacco botanical material may supplement the flavour profile of any aerosol produced. For example, a non-tobacco botanical material may be selected which has a relatively neutral flavour profile. A neutral flavour profile may be described as a flavour profile which contains few intense flavours and/or one which readily accepts the loading of top flavours, without significantly affecting their perception.

In some embodiments, the fibrous material may be called a substrate. The aerosol generating material may be described as comprising first and second substrates, corresponding to the first fibrous material comprising a tobacco material and the second fibrous material comprising a non-tobacco botanical material. In some embodiments, an aerosol generating material comprises a first fibrous material comprising a tobacco material, a second fibrous material comprising a non-tobacco botanical material, an active, and a binder. In certain circumstances, consumers may wish to experience the effects of an active other than nicotine, such as one or more of those described hereinabove.

The botanical material may be any non-tobacco botanical material. For example, the material may be derived from species which are members of the Asteracae family, the Fabaceae family, the Myrtaceae family, Apiaceae family, Camellia taliensis, the Solanaceae family, the Brassicaceae family, the Caricaceae family, the Asclepiadaceae family, the Equisetaceae family, the Oleaceae family, the Lamiaceae family, and tisanes. For example, the non-tobacco botanical material may be selected from the Matricaria species, such as chamomile; the Pimpinella anisum species, such as anise; the Foeniculum vulgare species, such as fennel; jasmine; lavender; cloves; eucalyptus, and the species Aspalathus linearis, such as rooibos.

In some embodiments, the non-tobacco botanical material is selected from a botanical material which comprises favourable aroma properties for use in a non- combustible aerosol provision system. For example, the non-tobacco botanical material may comprise relatively few aroma compounds compared to a traditional tobacco material; therefore, an aerosol produced from a non-tobacco botanical material may have a different profile of volatile compounds compared to an aerosol produced from a tobacco material. The non-tobacco botanical material may deliver an aerosol which is considered favourable by a consumer of tobacco-based delivery systems. In some embodiments, a non-tobacco botanical material may produce an aerosol, when heated, with a sensorial experience that is comparable to that provided by a conventional combustible product, such as a cigarette. In some embodiments, the non-tobacco botanical material is selected from seed-producing plants which do not develop persistent woody tissue and which are often valued for their medicinal or sensorial characteristics. In some embodiments, it may be preferable to provide an aerosol generating material, for use in a non-combustible aerosol provision system which does not comprise any tobacco plant material.

As used herein, the term "tobacco material" refers to a material derived from a plant of the Nicotiana species. The selection of the plant of the Nicotiana species is not limited, and the types of tobacco or tobaccos used may vary. 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, leaf tobacco, tobacco stem, reconstituted tobacco and/or tobacco extract. As used herein, "leaf tobacco" means cut lamina tobacco. In some embodiments, the tobacco material is selected from flue-cured or Virginia, Burley, sun-cured, Maryland, dark-fired, dark air cured, light air cured, Indian air cured, Red Russian and Rustica tobaccos, and mixtures thereof, as well as various other rare or specialty tobaccos, green or cured. Tobacco material produced via any other type of tobacco treatment which could modify the tobacco taste, such as fermented tobacco or genetic modification or crossbreeding techniques, is also within the scope of the present disclosure. For example, it is envisaged that tobacco plants may be genetically engineered or crossbred to increase or decrease production of components, characteristics or attributes. In some embodiments, the tobacco material is sun-cured tobacco, selected from Indian Kurnool and Oriental tobaccos, including Izmir, Basma, Samsun, Katerini, Prelip, Komotini, Xanthi and Yambol tobaccos. In some embodiments, the tobacco material is dark air cured tobacco, selected from Passanda, Cubano, Jatin and Besuki tobaccos. In some embodiments, the tobacco material is light air cured tobacco, selected from North Wisconsin and Galpao tobaccos. In some embodiments, the tobacco material is selected from Brazilian tobaccos, including Mata Fina and Bahia tobaccos. In some embodiments, the tobacco material is selected from criollo, Piloto Cubano, Olor, Green River, Isabela DAC, White Pata, Eluru, Jatim, Madura, Kasturi, Connecticut Seed, Broad Leaf, Connecticut, Pennsylvanian, Italian dry air cured, Paraguayan dry air cured and One Sucker tobaccos.

For the preparation of smoking/vaping or smokeless tobacco products, plants of the Nicotiana species may be subjected to a curing process. Certain types of tobaccos may be subjected to alternative types of curing processes, such as fire curing or sun curing. Preferably, but not necessarily, harvested tobaccos that are cured are aged.

The tobacco can be harvested in different stages of growth, for example when the plant has reached a level of maturity and the lower leaves are ready for harvest whilst the upper leaves are still in development.

In some embodiments, at least one portion of the plant of the Nicotiana species (e.g., at least a portion of the tobacco material) is employed in an immature form. That is, in some embodiments, the plant, or at least one portion of that plant, is harvested before reaching a stage normally regarded as ripe or mature.

In some embodiments, at least a portion of the plant of the Nicotiana species (e.g. at least a portion of the tobacco material) is employed in a mature form. That is, in some embodiments, the plant, or at least one portion of that plant, is harvested when that plant (or plant portion) reaches a point that is traditionally viewed as being ripe, over-ripe or mature, which can be accomplished through the use of tobacco harvesting techniques conventionally employed by farmers. Both Oriental tobacco and Burley tobacco plants can be harvested. Also, the Virginia tobacco leaves can be harvested or primed depending upon their stalk position.

The Nicotiana species may be selected for the content of various compounds that are present in the plant. For example, plants may be selected on the basis that those plants produce relatively high quantities of one or more of the compounds desired to be isolated (i.e. the volatile compounds of interest). In certain embodiments, plants of the Nicotiana species are specifically cultivated for their abundance of leaf surface compounds. Tobacco plants may be grown in green-houses, growth chambers, or outdoors in fields, or grown hydroponically.

Various parts or portions of the plant of the Nicotiana species may be utilised. In some embodiments, the whole plant, or substantially the whole plant, is harvested and employed as such. As used herein, the term "substantially the whole plant" means that at least 90% of the plant is harvested, such as at least 95% of the plant, such as at least 99% of the plant. Alternatively, in some embodiments, various parts or pieces of the plant are harvested or separated for further use after harvest. In some embodiments, the tobacco material is selected from the leaves, stems, stalks of the plant, and various combinations of these parts. The tobacco material of the disclosure may thus comprise an entire plant or any portion of a plant of the Nicotiana species.

The tobacco material can be reconstituted tobacco, such as paper reconstituted tobacco, extruded tobacco or bandcast reconstituted tobacco, or a combination of bandcast reconstituted tobacco and another form of tobacco, such as tobacco granules.

Paper reconstituted tobacco refers to tobacco material formed by a process in which tobacco feedstock is extracted with a solvent to afford an extract of solubles and a residue comprising fibrous material, and then the extract (usually after concentration, and optionally after further processing) is recombined with fibrous material from the residue (usually after refining of the fibrous material, and optionally with the addition of a portion of non-tobacco fibres) by deposition of the extract onto the fibrous material. The process of recombination resembles the process for making paper.

The paper reconstituted tobacco may be any type of paper reconstituted tobacco that is known in the art. In a particular embodiment, the paper reconstituted tobacco is made from a feedstock comprising one or more of tobacco strips, tobacco stems, and whole leaf tobacco. In a further embodiment, the paper reconstituted tobacco is made from a feedstock consisting of tobacco strips and/or whole leaf tobacco, and tobacco stems. In some embodiments, the paper-reconstituted tobacco is made from expanded tobacco. For example, the paper-reconstituted tobacco can be made from ground expanded tobacco.

The paper reconstituted tobacco for use in the tobacco material described herein may be prepared by methods which are known to those skilled in the art for preparing paper reconstituted tobacco. In some embodiments, the first fibrous material comprising tobacco material may comprise an amorphous solid. In some embodiments, the first fibrous material comprises an amorphous solid which is crimped and gathered. In some embodiments, the amorphous solid is provided on a support for supporting the sheet of aerosol generating material. In some embodiments, the sheet of aerosol generating material and the support may be in the form of a laminate.

In some embodiments, the support may comprise the second fibrous material comprising a non-tobacco botanical material. A method of preparing an amorphous solid may include: forming a slurry comprising a gelling agent, an aerosol former, and a tobacco material; forming a layer of the slurry; and drying the slurry to provide an amorphous solid.

The amorphous solid may be formed by a casting process of the type generally comprising casting a slurry onto a conveyor belt of other support surface, drying the case slurry to form a sheet of amorphous solid and removing the sheet of amorphous solid from the support surface. The sheet may be cast into a continuous sheet. The second fibrous material may be prepared in a similar manner to the first fibrous material. For example, the second fibrous material may be a reconstituted material, may be prepared by a papermaking process, the material may be extruded; the material may be bandcast; the material may be granules; or any other processing known to the person skilled in the art may be used.

In some embodiments, the aerosol generating material comprises a single sheet of material which may be shredded, crimped and gathered, or collated in any other manner. In such an embodiment the fist fibrous material and the second fibrous material may be combined in the same sheet or combined in the same amorphous solid. The first and second fibrous materials may be collated using any of the processing techniques disclosed herein. For example, the first and second fibrous materials may be combined in a papermaking process; in an extruded material; in a bandcast material; or in another form typically used in the tobacco industry.

In some embodiments, the first fibrous material and the second fibrous material are separate components of the aerosol generating material. For example, the first fibrous material and the second fibrous material can be prepared separately, according to any of the preparation methods disclosed herein, and subsequently combined to form the aerosol generating material. Preparing separate first and second fibrous materials may provide a different sensorial experience to a consumer compared to an aerosol generating material comprising a mixed/blended first and second fibrous material.

In some embodiments, the tobacco material may relate to "treated tobacco". As used herein, the term "treated tobacco" refers to tobacco that has undergone a treatment process.

In some embodiments, the treated tobacco material may have a low microbial content. As used herein, the term 'microbial content' refers to the amount of microorganisms present. The term 'microbial' may be used interchangeably with the term 'microbiological'. In some embodiments, the APC of the tobacco material may represent the microbial content of the tobacco material. In some embodiments, an APC of up to about 1000 CFU/g may be considered to be a low microbial content. In some embodiments, an APC of up to about 100 CFU/g may be considered to be a low microbial content. In some embodiments, an APC of up to about 20 CFU/g may be considered to be a low microbial content. In some embodiments, the microbial content of the treated tobacco material is lower than the microbial content of the untreated tobacco material.

Alternatively or in addition, the treated tobacco material may have a low mould content. The treated tobacco material may have a mould content of up to about 10 CFU/g. In some embodiments, the mould content of the treated tobacco material is less than 10 CFU/g, less than 8 CFU/g, less than 6 CFU/g, less than 4 CFU/g or less than 2 CFU/g. The mould content of the treated tobacco material may be lower than and/or about the same level as the mould content of the untreated tobacco material.

Alternatively or in addition, the treated tobacco material may have a low yeast content. The treated tobacco material may have a yeast content of up to about 10 CFU/g. In some embodiments, the yeast content of the treated tobacco material is less than 10 CFU/g, less than 8 CFU/g, less than 6 CFU/g, less than 4 CFU/g or less than 2 CFU/g. The yeast content of the treated tobacco material may be lower than and/ or about the same level as the yeast content of untreated tobacco material.

Alternatively or in addition, the treated tobacco material may have a low coliform content. The treated tobacco material may have a coliform bacteria content of up to about 10 CFU/g at 35°C and/ or 45°C. In some embodiments, the coliform content of the treated tobacco material is less than 10 CFU/g, less than 8 CFU/g, less than 6 CFU/g, less than 4 CFU/g or less than 2 CFU/g at 35°C and/or 45°C. In some embodiments, the coliform content of the treated tobacco material is o CFU/g at 35°C and/or 45°C. The coliform content of the treated tobacco material may be lower than and/ or about the same level as the coliform content of the untreated tobacco material.

The low microbial, mould, yeast and/or coliform content of the treated tobacco material may have the effect that the tobacco material is in a good physical state and/or is well preserved. The low microbial, mould, yeast and/ or coliform content may minimise the occurrence of decay and/ or rot in the tobacco material, thus minimising the need to discard decayed and/or rotten tobacco material, offering considerable advantages in terms of waste reduction and costs.

The aerosol generating material comprises a second fibrous material comprising a non-tobacco botanical material in an amount of greater than about 50% by weight of the aerosol generating material. In some embodiments, therefore, it can be described that the aerosol generating material comprises a first fibrous material comprising a tobacco material in an amount of less than about 50% by weight of the aerosol generating material. In some embodiments, the aerosol generating material comprises the second fibrous material comprising a non-tobacco botanical material in an amount of greater than about 55% by weight of the aerosol generating material, such as greater than about 60%, greater than about 65%, greater than about 70%, greater than about 75%, greater than about 80%, greater than about 85%, greater than about 90%, greater than about 95% by weight of the aerosol generating material. In some embodiments, the aerosol generating material comprises the first fibrous material comprising a tobacco material in an amount of less than about 50% by weight of the aerosol generating material, such as less than about 45%, less than about 40%, less than about 35%, less than about 30%, less than about 25%, less than about 20%, less than about 15%, less than about 10%, less than about 5% by weight of the aerosol generating material.

In some embodiments, the aerosol generating material comprises the first fibrous material comprising a tobacco material in an amount of about 10% by weight of the aerosol generating material and the second fibrous material comprising a non- tobacco botanical material in an amount of about 90% by weight of the aerosol generating material.

In some embodiments, the aerosol generating material comprises the first fibrous material comprising a tobacco material in an amount of about 20% by weight of the aerosol generating material and the second fibrous material comprising a nontobacco botanical material in an amount of about 80% by weight of the aerosol generating material.

In some embodiments, the aerosol generating material comprises the first fibrous material comprising a tobacco material in an amount of about 15% by weight of the aerosol generating material and the second fibrous material comprising a nontobacco botanical material in an amount of about 85% by weight of the aerosol generating material. In some embodiments, the aerosol generating material comprises the first fibrous material and the second fibrous material in a ratio of about 1 :3 to about 1: 10, such as in a ratio of about 1 :4 to about 1 : 10, such as in a ratio of about 1 : 5 to about 1 : 10, such as in a ratio of about 1 :6 to about 1 : 10, such as in a ratio of about 1 :7 to about 1 : 10, such as in a ratio of about 1:8 to about 1 : 10, such as in a ratio of about 1 :9. As used herein, the term "fill value" is a measure of the ability of a material to occupy a specific volume at a given moisture content. A high fill value indicates that a lower weight of material is required to produce a rod at acceptable hardness/firmness levels of a given circumference, volume and length than is required with a material of lower fill value.

In some embodiments, the non-tobacco botanical material has a fill value of about 4 cm³/g to about 7 cm³/g. For example, the fill value may be about 4.5 cm³/g to about 7 cm³/g, such as about 5 cm³/g to about 7 cm³/g, such as about 5 cm³/g to about 6.5 cm³/g, such as about 5.5 cm³/g to about 6.5 cm³/g.

In some embodiments, the aerosol generating material has a fill value of about 4 cm³/g to about 7 cm³/g. For example, the fill value may be about 4.5 cm³/g to about 7 cm³/g, such as about 5 cm³/g to about 7 cm³/g, such as about 5 cm³/g to about 6.5 cm³/g, such as about 5.5 cm³/g to about 6.5 cm³/g.

Test Method A

Fill value is measured according to the following process. A 15 g sample of a non-tobacco botanical material was deposited into a 60 mm diameter cylinder of a densimeter and then the material was compressed with a 1kg piston for 30 seconds. The height of the piston in the densimeter as well as the moisture content of the samples were measured. The fill values of the samples were calculated according to the following formulae.

The volume occupied by the botanical material when compressed was determined using Formula 1 :

Formula 1

Volume r = radius of cylinder (cm) h = measured height

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

The fill value was corrected to account for its moisture content using Formula 3:

FVo = Fill value at moisture content Mo%

FV = Fill value determined at moisture content M% (cm³/10g)

Mo = 13.5% (target moisture content)

M = Actual moisture content of botanical material (%)

0.8 = constant Moisture content (oven volatiles) is measured as the reduction in mass when a sample is dried in a forced draft oven at a temperature regulated to 100°C ± 1°C for three hours ± 0.5 minutes. After drying, the sample is cooled in a desiccator to room temperature for approximately 30 minutes, to allow the sample to cool.

Using materials having a relatively high fill value may lead to reductions in the weight of the aerosol-generating material and thus the article because a lower mass of the expanded material is required to fill a given volume of the article compared with materials that have a relatively low fill value.

Expanded materials have typically been subjected to an expansion process.

Expansion involves an increase in the area and spacing between fibres of the material. After being subjected to the expansion process, the material has a higher fill value, but lower density, than the material prior to the expansion process. Expansion processes may be performed on non-tobacco botanical materials and tobacco materials.

Typically, an expansion process involves rapidly increasing the temperature and/or the pressure of a solid material comprising a fluid (e.g. water) such that the fluid is rapidly released from the material. This usually involves a change in phase of the fluid (e.g. water turns from a liquid to a gas) and an increase in the volume of the fluid. The rapid release and expansion in the fluid causes it to be released from the solid material. At the same time, the solid material expands to occupy a greater volume. Whilst fluid is often present in the solid material naturally, additional fluid can be introduced by impregnation or absorption of the fluid into the solid material (optionally under pressure).

One such expansion process that can be used is dry ice expansion. Dry ice expansion involves permeating the material with liquid carbon dioxide before warming. The resulting carbon dioxide gas forces the material to expand. Additional methods include the treatment of material with solid materials which, when heated, decompose to produce gases which serve to expand the material. Other methods include the treatment of materials with gas-containing liquids, such as carbon dioxide-containing water, under pressure to impregnate the material with the liquid. The impregnated material is then heated, or the pressure reduced, to cause release of the gas and expansion of the material. Additional techniques involve the treatment of material with gases which react to form solid chemical reaction products within the material, for example carbon dioxide and ammonia to form ammonium carbonate. These solid reaction products may subsequently be decomposed by heat to produce gases within the material which cause expansion of the material upon their release.

The tobacco material to be expanded can be in a variety of forms, such as lamina or stem. For example, tobacco stems may be expanded by utilizing various types of heat treatment or microwave energy. Freeze-drying of botanical material can also be employed to obtain an increase in volume (and thus fill value). Consecutive drying techniques may also be used to expand cut stems, such as air drying, and fluidized bed drying, etc. Similar techniques can be employed to expand nontobacco botanical materials, such as those described herein. In some embodiments, the tobacco material is dry ice expanded tobacco material (DIET) or expanded tobacco stem.

In some embodiments, the aerosol generating material comprises a nicotine source. For example, the nicotine source may be the tobacco material itself.

In some embodiments, the aerosol generating material comprises at least one additional nicotine salt. For example, the aerosol generating material may additionally comprise nicotine benzoate, nicotine levulinate, nicotine lactate, nicotine citrate, or mixtures thereof. When the aerosol generating material comprises two or more nicotine salts, the total amount of nicotine salt in the aerosol generating material may be from about 1% to about 10%, by weight on a dry weight basis. For example, the aerosol generating material may have a total nicotine salt amount of from about 1% to about 9% by weight on a dry weight basis; from about 1% to about 8% by weight on a dry weight basis; from about 2% to about 6% by weight on a dry weight basis; from about 3% to about 5% by weight on a dry weight basis.

In some embodiments, the aerosol generating material comprises free base nicotine and an organic acid. In some embodiments, the acid is selected from the group consisting of levulinic acid, lactic acid, benzoic acid, citric acid, 2-methylbutyric acid, or 2-methylvaleric acid. In some embodiments, the acid is benzoic acid. In some embodiments, the acid is levulinic acid. The total amount of the acid may be from about 0.1% to about 5% by weight of the aerosol-generating material. For example, the total amount of the acid may be from about 0.1% to about 5%, from about 0.5% to about 5%, from about 1% to about 5%, from about 1.5% to about 5%, from about 2% to about 5%, or from about 2.5% to about 5% by weight of the aerosol-generating material. For example, the total amount of the acid may be from about 2.5% to about 5%, from about 2.5% to about 4.5%, from about 2.5% to about 4%, from about 2.5% to about 3.5%, or from about 2.5% to about 3% by weight of the aerosol generating material. In some embodiments, the aerosol generating material comprises an aerosol former/aerosol former material. The total amount of aerosol former may be from about 10% to about 30% by weight of the aerosol generating material. In some embodiments, the total amount of the aerosol former is from about 10% to about 28% by weight of the aerosol generating material, such as from about 10% to about 26%, such as from about 10% to about 24%, such as from about 10% to about 22%, such as from about 10% to about 20%, such as from about 10% to about 18%, such as from about 10% to about 16%, such as from about 12% to about 16% such as from about 14% to about 16%, by weight of the aerosol generating material. In some embodiments, the total amount of the aerosol former material is about 15% by weight of the aerosol generating material. When the aerosol generating material comprises an aerosol former in more than about 20%, by weight of the aerosol generating material, the aerosol generating may become "sticky" during storage, which may lead to processability issues. In this context, an "aerosol former " is an agent, or material, that promotes the generation of an aerosol. An aerosol former may promote the generation of an aerosol by promoting an initial vaporisation and/or the condensation of a gas to an inhalable solid and/or liquid aerosol. In some embodiments, an aerosol former may improve the delivery of flavour from the aerosol generating material.

The aerosol former material has been found to improve the sensory performance of an article for use with an aerosol generation device comprising the aerosol generating material, by helping to transfer compounds such as flavour compounds from the fibrous material to the consumer. In some embodiments, the aerosol former material described herein is flavoured and/or comprises a flavour as described herein. In general, any suitable aerosol former may be included in the aerosol generating material of the invention. Suitable aerosol formers include, but are not limited to: a polyol such as sorbitol, glycerol, and glycols like propylene glycol or triethylene glycol; a non-polyol such as monohydric alcohols, high boiling point hydrocarbons, acids such as lactic acid, glycerol derivatives, esters such as diacetin, triacetin, triethylene glycol diacetate, triethyl citrate or myristates including ethyl myristate and isopropyl myristate and aliphatic carboxylic acid esters such as methyl stearate, dimethyl dodecanedioate and dimethyl tetradecanedioate. In some embodiments, the aerosol former is selected from the group consisting of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, propylene carbonate, and mixtures thereof.

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

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

The aerosol-generating material may comprise expanded non-tobacco botanical material and/or expanded tobacco e.g. DIET. An aerosol generating material may be included in an amount of about 10% by weight of the aerosol-generating material.

Examples A selection of aerosol generating materials were prepared according to the values in Table 1.

Table 1 The advantages and features of the disclosure are of a representative sample of embodiments only, and are not exhaustive and/or exclusive. They are presented only to assist in understanding and teach the claimed features. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications maybe made without departing from the scope and/or spirit of the disclosure.

Claims

- 2. - Claims

1. An aerosol generating material comprising: a first fibrous material comprising a tobacco material, and a second fibrous material comprising a non-tobacco botanical material, wherein the aerosol generating material comprises the second fibrous material in an amount of greater than about 50% by weight of the aerosol generating material.

2. The aerosol generating material according to claim 1, wherein the nontobacco botanical material is selected from the list consisting of rooibos, star anise, fennel, mint, and combinations thereof, preferably wherein the botanical material is rooibos.

3. The aerosol generating material according to claim 1 or claim 2, wherein the botanical material has a fill value of about 4 cm³/g to about 7 cm³/g.

4. The aerosol generating material according to any one of claims 1 to 3, wherein the tobacco material is selected from the list consisting of dryice expanded tobacco (DIET), leaf tobacco, tobacco stem, tobacco fibre, ground tobacco, reconstituted tobacco, extruded tobacco, lamina tobacco and combinations thereof, preferably wherein the tobacco material comprises Virginia tobacco.

5. The aerosol generating material according to any one of claims 1 to 4, wherein the first fibrous material is present in an amount less than about 30% by weight of the aerosol generating material.

6. The aerosol generating material according to any one of claims 1 to 5, wherein the first fibrous material and the second fibrous material are included in a ratio of about 1 :3 to about 1 : 10.

7. The aerosol generating material according to any one of claims 1 to 6, further comprising a nicotine source.

8. The aerosol generating material according to claim 7, wherein the nicotine source is a nicotine salt, such as nicotine benzoate, nicotine levulinate, nicotine citrate, nicotine lactate, or combinations thereof.

9. The aerosol generating material according to claim 8, wherein the nicotine source is free base nicotine, preferably further comprising an organic acid, such as lactic acid, levulinic acid, benzoic acid, citric acid, 2-methylbutyric acid, 2-methylvaleric acid, and mixtures thereof.

10. The aerosol generating material according to any one of claims 1 to 9, further comprising an aerosol former, such as an aerosol former selected from the list consisting of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

11. The aerosol generating material according to claim 10, wherein the aerosol former is included in an amount from about 10% to about 30% on a dry weight basis.

12. The aerosol generating material according to any one of claims 1 to 11, comprising a water content of about 4% to about 20%.

13. The aerosol generating material according to any one of claims 1 to 12, wherein the aerosol generating material has a thickness of about 200 pm to about 450 pm.

14. An aerosol generating rod comprising an aerosol generating material according to any one of claims 1 to 13.

15. A delivery system comprising an aerosol generating material according to any one of claims 1 to 13, or the aerosol generating rod according to claim 14.