Abstract: The invention relates to a method for the preparation of a sheet including a homogenized material containing alkaloids, said method comprising: —forming a mixture comprising a reducing sugar and particles of a material containing alkaloids; —extruding the mixture; —adding water to the extruded mixture to form a slurry; and —casting the slurry into a sheet.

Abstract: A heater assembly for an aerosol-generating device is provided, including: an elongate heating chamber configured to heat an aerosol-forming substrate; and a heating element arranged around the elongate heating chamber, the elongate heating chamber having a first length and the heating element having a second length, the first length of the elongate heating chamber being greater than the second length of the heating element, such that there is a proximal distance between a proximal end of the elongate heating chamber and a proximal end of the heating element, and the proximal distance being between 0.1 millimeter and 4 millimeters. An aerosol-generating device including the heater assembly, and an aerosol-generating system including the aerosol-generating device and an aerosol-generating article, are also provided.

Abstract: An aerosol-generating article for producing an inhalable aerosol upon heating is provided, the aerosol-generating article including: a rod of aerosol-generating substrate, the aerosol-generating substrate including homogenised plant material including tobacco particles and at least 2.5 percent by weight of non-tobacco plant flavour particles, on a dry weight basis, the non-tobacco plant flavour particles including particles of eucalyptus, star anise, clove, ginger, rosemary, or combinations thereof; an upstream element upstream of the rod of aerosol-generating substrate and abutting an upstream end of the rod of aerosol-generating substrate; and a downstream section arranged downstream of the rod of aerosol-generating substrate and in axial alignment with the rod of aerosol-generating substrate, the downstream section including one or more downstream elements.

Abstract: An aerosol-generating article including an aerosol-generating substrate is provided, the aerosol-generating substrate formed of a homogenised rosemary material including between 1 percent by weight and 25 percent by weight rosemary particles, between 5 percent and 30 percent by weight of an aerosol former, and between 1 percent by weight and 10 percent by weight of binder, on a dry weight basis. An aerosol-generating substrate, an aerosol-generating system, and an aerosol produced upon heating of an aerosol-generating substrate, are also provided.

Abstract: There is provided a heated aerosol-generating article for producing an inhalable aerosol, the heated aerosol-generating article including: an aerosol-forming substrate that is a homogenized tobacco material including tobacco, a fat having a melting point between 20° C. and 50° C., and one or more aerosol-formers, the homogenized tobacco material containing at least 60% tobacco on a dry weight basis. A homogenized tobacco material is also provided.

Abstract: A method of forming homogenized tobacco material is provided, including forming a homogenized slurry including tobacco powder; casting the homogenized slurry onto a moving belt; incorporating a porous reinforcement sheet into the cast homogenized slurry; and drying the cast homogenized slurry with the incorporated porous reinforcement sheet to form the homogenized tobacco material, the porous reinforcement sheet having anisotropic properties such that the porous reinforcement sheet has a higher tensile strength in a longitudinal direction thereof than in a transverse direction thereof.

Abstract: An aerosol-generating article for an aerosol-generating device including a heating element is provided, the aerosol-generating article including: an aerosol-forming substrate including homogenised tobacco material; a support element disposed immediately downstream of the aerosol-forming substrate; an aerosol-cooling element disposed downstream of the support element; and an outer wrapper circumscribing the aerosol-forming substrate, the support element, and the aerosol-cooling element, the support element abutting the aerosol-forming substrate.

Abstract: An aerosol-generating article is provided, including an aerosol-forming substrate; a support element located immediately downstream of the aerosol-forming substrate; an aerosol-cooling element located downstream of the support element; and an outer wrapper circumscribing the aerosol-forming substrate, the support element and the aerosol-cooling element. The support element abuts the aerosol-forming substrate. The aerosol-forming substrate is penetrable by a heating element of an aerosol-generating device.

Abstract: An aerosol-generating article for producing an inhalable aerosol upon heating is provided, the aerosol-generating article including: a rod of aerosol-generating substrate, the rod including a sheet of homogenised plant material, the homogenised plant material being arranged longitudinally between an upstream end of the rod and a downstream end of the rod; and a wrapper circumscribing the homogenised plant material, the sheet of homogenised plant material including a plurality of formed fluid passageways extending through a thickness of the sheet and configured to establish a fluid communication between opposite sides of the sheet. A method of making a rod for an aerosol-generating substrate in an aerosol-generating article, a rod for an aerosol-generating substrate in an aerosol-generating article, and an aerosol-generating system, are also provided.

Abstract: An aerosol-generating article is provided, including: a substrate portion containing an aerosol-forming substrate; and a connect portion disposed at one end of the aerosol-generating article in direct abutment with the substrate portion, the connect portion having a tubular empty core structure, the substrate portion having a length of between 20 millimeters and 60 millimeters, and a diameter of between 4 millimeters and 7 millimeters, the aerosol-forming substrate including an aerosol former, and an amount of the aerosol former ranges between 6 percent and 20 percent by weight on a dry weight basis of the aerosol-forming substrate. An aerosol-generating system including the aerosol-generating article and an aerosol-generating device, and a method for manufacturing the aerosol-generating article, are also provided.

Abstract: The invention relates to a method for the preparation of a material containing alkaloids, said method comprising:—forming a mixture comprising a reducing sugar and particles of a material containing alkaloids;—extruding the mixture, wherein extruding includes: feeding the mixture to an extruder; heating the mixture to a first temperature lower than or equal to about 190 Celsius degrees; cooling the mixture from the first temperature to a second temperature lower than or equal to about 70 Celsius degrees; and discharging an extruded mixture from the extruder.

Abstract: There is provided a method of making rods having predetermined values of cross-sectional porosity, and a cross-sectional porosity distribution value for use as an aerosol-forming substrate in a heated aerosol-generating article, including providing a continuous sheet of aerosol-forming material having a specified width and a specified thickness; gathering the sheet transversely relative to a longitudinal axis thereof; circumscribing the gathered sheet with a wrapper to form a continuous rod; severing the rod into a plurality of discrete rods; determining values of cross-sectional porosity and cross-sectional porosity distribution for at least one of the discrete rods; and controlling one or more manufacturing parameters to ensure that the cross-sectional porosity and cross-sectional porosity distribution values of subsequent rods are within the predetermined values.

Abstract: The invention relates to a method for the preparation of a homogenized tobacco material, said method comprising: —pulping and refining cellulose fibres to obtain fibres having a mean size comprised between about 0.2 millimetres and about 4 millimetres; —grinding a blend of tobacco of one or more tobacco types to a tobacco powder having a mean size comprised between about 0.03 millimetres and about 0.12 millimetres; —combining the pulp with the tobacco powder blend of different tobacco types and with a binder in an amount comprised between about 1 percent and about 5 percent in dry weight basis of the total weight of the homogenized tobacco material, so as to form a slurry; —homogenizing the slurry; and—forming the homogenized tobacco material from the slurry.

Abstract: The invention relates to a method for the preparation of a sheet including a homogenized material containing alkaloids, said method comprising: —forming a mixture comprising a reducing sugar and particles of a material containing alkaloids; —extruding the mixture; —adding water to the extruded mixture to form a slurry; and—casting the slurry into a sheet.

Abstract: The invention relates to a method for the preparation of a sheet including a homogenized material containing alkaloids, said method comprising: —forming a mixture comprising particles of a material containing alkaloids and a starch component, and a quantity of a first additive comprising a component selected from the group consisting of water, aerosol-former and binder, wherein the quantity of the first additive is comprised between about 0.1 percent and about 50 percent by weight of the total weight of the mixture; —applying to the mixture a mechanical energy of at least about 20 watt-hour per kilogram of the mixture; —combining the mixture with a quantity of a second additive comprising a component selected from the group consisting of water, aerosol-former, and binder, to form a slurry; and —forming a sheet from the slurry.

Abstract: There is provided a heated aerosol-generating article for producing an inhalable aerosol, the article including an aerosol-forming substrate that is a homogenized tobacco material including tobacco and a wax having a melting point between 50° C. and 150° C., a total content of wax in the homogenized tobacco material being between 5 weight percent and 15 weight percent on a dry weight basis, and the wax being evenly distributed within the homogenized tobacco material. A homogenized tobacco material and a method of making a homogenized tobacco material are also provided.

Abstract: The present invention relates to a method of preparation of a slurry for the production of a homogenized tobacco material, said method comprising: —suspending a binder in an aerosol-former to form a suspension; —creating a cellulose pulp from cellulose fibers and water; —providing a tobacco powder blend; and —combining said suspension of binder in aerosol-former, said cellulose pulp and said tobacco powder blend to form said slurry.

Abstract: There is provided a method of making rods having predetermined values of cross-sectional porosity, and a cross-sectional porosity distribution value for use as an aerosol-forming substrate in a heated aerosol-generating article, including providing a continuous sheet of aerosol-forming material having a specified width and a specified thickness; gathering the sheet transversely relative to a longitudinal axis thereof; circumscribing the gathered sheet with a wrapper to form a continuous rod; severing the rod into a plurality of discrete rods; determining values of cross-sectional porosity and cross-sectional porosity distribution for at least one of the discrete rods; and controlling one or more manufacturing parameters to ensure that the cross-sectional porosity and cross-sectional porosity distribution values of subsequent rods are within the predetermined values.

Abstract: There is provided a method of making rods having predetermined values of cross-sectional porosity, and a cross-sectional porosity distribution value for use as an aerosol-forming substrate in a heated aerosol-generating article, including providing a continuous sheet of aerosol-forming material having a specified width and a specified thickness; gathering the sheet transversely relative to a longitudinal axis thereof; circumscribing the gathered sheet with a wrapper to form a continuous rod; severing the rod into a plurality of discrete rods; determining values of cross-sectional porosity and cross-sectional porosity distribution for at least one of the discrete rods; and controlling one or more manufacturing parameters to ensure that the cross-sectional porosity and cross-sectional porosity distribution values of subsequent rods are within the predetermined values.

Abstract: There is provided a heated aerosol-generating article for producing an inhalable aerosol, the article including an aerosol-forming substrate that is a homogenized tobacco material including tobacco and a wax having a melting point between 50° C. and 150° C., a total content of wax in the homogenized tobacco material being between 5 weight percent and 15 weight percent on a dry weight basis, and the wax being evenly distributed within the homogenized tobacco material. A homogenized tobacco material and a method of making a homogenised tobacco material are also provided.