Aerosol-generating material

Abstract

A process for preparing an aerosol generating material including forming a first composition having a first binder and an aerosol former, forming a second composition having a tobacco material, a filler and optionally a second binder, combining the first composition and the second composition to form a mixture of the first composition and the second composition, the mixture including the first binder, the second binder and the filler in a total amount of between about 5% and about 15% by weight of the mixture and processing the mixture of the first composition and the second composition to form the aerosol generating material.

1 . A process for preparing an aerosol generating material comprising:
 forming a first composition comprising a first binder and an aerosol former;   forming a second composition comprising a tobacco material, a filler and optionally a second binder;   combining the first composition and the second composition to form a mixture of the first composition and the second composition, the mixture comprising the first binder, the second binder and the filler in a total amount of between about 5% and about 15% by weight of the mixture; and   processing the mixture of the first composition and the second composition to form the aerosol generating material.   
     
     
         2 . A process as claimed in  claim 1 , wherein processing the mixture of the first composition and the second composition comprises extruding the mixture to form a sheet of the aerosol generating material. 
     
     
         3 . A process as claimed in  claim 2 , wherein the process comprises drying the sheet of aerosol generating material. 
     
     
         4 . A process as claimed in  claim 1 , wherein the mixture of the first composition and the second composition has a volatile content of greater than about 20 wt %. 
     
     
         5 . A process as claimed in  claim 1 , wherein the aerosol generating material has a volatile content that is less than the volatile content of the mixture of the first composition and the second composition. 
     
     
         6 . A process as claimed in  claim 1 , wherein the aerosol generating material has a volatile content of less than about 20 wt %. 
     
     
         7 . A process as claimed in  claim 1 , wherein the tobacco material comprises particulate tobacco. 
     
     
         8 . A process as claimed in  claim 1 , wherein the tobacco material has a particle size distribution (D90) of 160-450 μm. 
     
     
         9 . A process as claimed in  claim 1 , wherein the first and second binders are the same or different. 
     
     
         10 . A process as claimed in  claim 1 , wherein a ratio of the first binder to the second binder is from 1:1 to about 1:10. 
     
     
         11 . A process as claimed in  claim 1 , wherein the mixture of the first composition and the second composition comprises the binder in an amount of greater than about 2% by weight of the mixture of the first composition and the second composition. 
     
     
         12 . A process as claimed in  claim 1 , wherein the mixture of the first composition and the second composition comprises the first binder, the second binder and the filler in a total amount of between 5 and 15% by weight of the mixture of the first composition and the second composition. 
     
     
         13 . A process as claimed in  claim 1 , wherein the first composition is in a liquid phase and the second composition is in a solid phase. 
     
     
         14 . A process as claimed in  claim 1 , wherein the mixture of the first composition and the second composition comprises the filler in an amount of greater than about 2% by weight of the mixture of the first composition and the second composition. 
     
     
         15 . A process as claimed in  claim 2 , wherein the process comprises shredding the sheet to form strips of the aerosol generating material. 
     
     
         16 . A process as claimed in  claim 3 , wherein the drying is performed at a temperature of less than about 100° C. 
     
     
         17 . A process as claimed in  claim 1 , wherein the mixture of the first composition and the second composition is formed by homogenizing homogenising the first composition and the second composition. 
     
     
         18 . An aerosol generating material prepared by a process as claimed in  claim 1 . 
     
     
         19 . An aerosol generating material as claimed in  claim 18 , wherein the aerosol generating material is in the form of a sheet or shredded sheet. 
     
     
         20 . An aerosol generating material as claimed in  claim 19 , wherein the sheet or shredded sheet has a burst strength of at least 150 g. 
     
     
         21 . An aerosol generating material as claimed in  claim 18 , wherein the sheet or shredded sheet has an area density of from about 170 g/m 2  to about 240 g/m2. 
     
     
         22 . An aerosol generating material as claimed in  claim 18 , wherein the sheet or shredded sheet has a tensile strength of from about 4 N/15 mm to about 20 N/15 mm. 
     
     
         23 . An aerosol generating material as claimed in  claim 18 , wherein the aerosol generating material comprises an amount of glycerol and/or nicotine that is between 0 and 5 wt % less than an amount of glycerol and/or nicotine comprised in the mixture of the first composition and the second composition. 
     
     
         24 . An article for use in a non-combustible aerosol-provision system comprising the aerosol generating material as claimed in  claim 18 . 
     
     
         25 . A non-combustible aerosol-provision system comprising the article as claimed in  claim 24 . 
     
     
         26 . Use of an aerosol generating material as claimed in  claim 18  in an article for use in a non-combustible aerosol-provision system.