Aerosol generating material

Abstract

To provide an aerosol generating material that can provide a uniform and continuous release of an active substance.SOLUTION: The invention provides an aerosol generating material to be included in an aerosol provision system, such as an apparatus for heating the aerosol generating material to volatilize at least one component of the aerosol generating material. The aerosol generating material comprises at least one particle comprising an active substance and at least one particle comprising a volatile component within the composition, where the volatile component has a vapor pressure at 20°C greater than or equal to the vapor pressure of the active substance at 20°C. The volatile component is present in the aerosol generating material.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to an aerosol-generating material for inclusion in an aerosol delivery system, such as an apparatus for heating the aerosol-generating material to volatilize at least one component of the aerosol-generating material, the aerosol-generating material comprising a volatile component in solid particulate form and an active agent. The present invention also relates to methods for preparing such materials and systems comprising them.

[0002] Smoking articles, such as cigarettes and cigars, burn tobacco to produce tobacco smoke during use. Attempts have been made to provide alternatives to these articles by creating products that release compounds without combustion. Examples of such products include so-called "non-combustion heat-to-burn" products, or tobacco heating devices or products, which release compounds by heating smokable material without burning it.

[0003] It is also known to include flavourants in smoking articles in order to impart a particular desired flavour to the aerosol produced by the smoking article. This impartation of flavour has been achieved in a variety of different ways, such as by the use of crushable capsules containing the flavour composition.

[0004] According to a first aspect of the present invention there is provided an aerosol-generating material comprising at least one particle incorporating a volatile component in solid form within a composition and at least one particle comprising an active substance, wherein the volatile component has a vapour pressure at 20°C that is greater than or equal to the vapour pressure of the active substance at 20°C, and wherein release of the active substance from the aerosol-generating material is controlled by competition with release of the volatile component.

[0005] In some embodiments, the aerosol generating material is for provision in an aerosol delivery system.

[0006] In some embodiments, the active agent is nicotine.

[0007] In some embodiments, the particles comprising an active agent are tobacco particles.

[0008] In some embodiments, the vapor pressure of the volatile component is at least 6 Pa at 20°C.

[0009] In some embodiments, the volatile component is a volatile flavoring, hi some embodiments, the volatile component is selected from the group consisting of menthol, limonene, linalool, camphene, and eucalyptol.

[0010] In some embodiments, the volatile ingredients do not have a unique or characteristic fragrance.

[0011] In some embodiments, the pH of the aerosol-forming material is from about 4 to about 9.5.

[0012] In some embodiments, the pH of the aerosol-forming material is increased by the addition of one or more bases or a basic buffer system.

[0013] In some embodiments, the one or more bases are selected from the group consisting of hydroxides, carbonates, and bicarbonates, and optionally, the one or more bases are selected from the group consisting of potassium hydroxide, sodium hydroxide, sodium carbonate, and sodium bicarbonate.

[0014] In some embodiments, particles comprising the active agent have an average diameter of 3 mm or less, 1 mm or less, 0.5 mm or less, or 0.3 mm or less.

[0015] In some embodiments, the particles incorporating a volatile component are particles consisting of the volatile component.

[0016] In some embodiments, particles incorporating a volatile component have an average diameter of 3 mm or less, 1 mm or less, 0.5 mm or less, or 0.3 mm or less.

[0017] In some embodiments, the aerosol generating material further comprises one or more aerosol forming agents, hi some embodiments, the aerosol forming agents are selected from the group consisting of glycerol, propylene glycol, and glyceryl triacetate.

[0018] In some embodiments, the aerosol-forming material further comprises one or more binders, hi some embodiments, the one or more binders are selected from the group consisting of thermoreversible gelling agents, such as gelatin; starch; polysaccharides; pectin; cellulose; cellulose derivatives, such as carboxymethylcellulose; and alginates.

[0019] In some embodiments, a precursor composition comprising volatile component particles and particles comprising an active agent is granulated or spheronized to form an agglomerated structure.

[0020] In some embodiments, a precursor composition comprising volatile component particles and particles comprising an active agent is extruded to form an aggregate structure.

[0021] In some embodiments, the aerosol-forming material is in the form of granules.

[0022] According to a second aspect of the present invention, there is provided an aerosol delivery system comprising an aerosol-generating material according to the first aspect.

[0023] In some embodiments, the system is an aerosol-generating material heating system that comprises an aerosol-generating material that is heated to volatilize volatile components, and optionally comprises a filter or filter element.

[0024] In some embodiments, the system is a hybrid system comprising an aerosol-generating material that is heated to volatilize a volatile component and a liquid that is heated to form a vapor, and optionally a filter or filter element.

[0025] In some embodiments, the aerosol-forming material is heated by steam.

[0026] In some embodiments, the liquid is a nicotine-free liquid.

[0027] In some embodiments, the device includes a means for heating a liquid to form a vapor, but does not include a separate means for heating the aerosol-forming material.

[0028] According to a third aspect of the invention, there is provided a method for preparing an aerosol-generating material comprising a volatile component for use in an aerosol delivery system, the method comprising incorporating the volatile component into a composition in solid form, the volatile component having a vapour pressure at 20°C that is equal to or greater than the vapour pressure of an active substance at 20°C.

[0029] In some embodiments, the aerosol-forming material is formed from a precursor composition that includes particles that include a volatile component and particles that include an active agent.

[0030] In some embodiments, the precursor composition is granulated or spheronized to form an aggregate structure.

[0031] In some embodiments, the precursor composition is extruded to form a coherent structure.

[0032] According to a fourth aspect of the present invention there is provided an apparatus for heating an aerosol-generating material to volatilise at least one component of the aerosol-generating material and a nicotine-free liquid which is heated to form a vapour, wherein the aerosol-generating material comprises an aerosol-generating material according to the first aspect, and the aerosol-generating material is heated by the vapour.

[0033] In some embodiments, the device includes a means for heating a liquid to form a vapor, but does not include a separate means for heating the aerosol forming material.

[0034] In some embodiments, the pH is increased by the addition of one or more bases or a basic buffer system.

[0035] According to a fifth aspect of the invention there is provided a particle incorporating a volatile component in solid form for use in controlling the release of nicotine in an aerosol-forming material, the volatile component having a vapour pressure at 20°C that is greater than or equal to the vapour pressure of the active substance at 20°C.

[0036] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0037] [Figure 1] 1 is a flow chart illustrating the major steps of a process according to an embodiment of the present invention. [Diagram 2] FIG. 2 is a schematic diagram of some extruded granules. [Diagram 3] FIG. 1 is a schematic cross-sectional view of a tobacco heating product for heating an aerosol-forming material to volatilize at least one component of the aerosol-forming material. [Figure 4] FIG. 1 is a schematic diagram of a hybrid system for heating an aerosol-forming material to volatilize at least one component of the aerosol-forming material. [Diagram 5] FIG. 1 is a schematic cross-sectional view of an example cartridge containing a plurality of particles of an aerosol-generating material. Detailed Description

[0038] The present invention relates to an aerosol-forming material comprising a volatile component in solid particulate form and nicotine, the aerosol-forming material being capable of releasing the volatile component and the active substance upon heating.

[0039] In some embodiments, the aerosol-forming material is in granular or monolithic form, hi some embodiments, the aerosol-forming material is in an aggregated structure, meaning that the aerosol-forming material is an agglomerate or cluster formed by fusing or adhering multiple particles together.

[0040] The aerosol-generating material can provide a homogeneous and sustained release of the active substance from the aerosol-generating material as a result of the presence of a volatile component in the aerosol-generating material that has a vapor pressure at 20°C that is equal to or greater than the vapor pressure of the active substance at 20°C. Without wishing to be bound by a particular theory, it is believed that the active substance and the volatile component compete to volatilize from the aerosol-generating material. It is believed that the presence of a volatile component that is easily volatilized upon heating inhibits the volatilization of the active substance and slows its release from the aerosol-generating material. This is particularly advantageous in tobacco heating devices and hybrid devices, where nicotine generally volatilizes quickly, resulting in an initial rapid release of nicotine, followed by a rapid drop in nicotine release, leading to inconsistent nicotine delivery and user experience.

[0041] Thus, in some embodiments of the present invention, the presence of a volatile component controls the release of the active agent from the aerosol-generating material, which is an unexpected and highly beneficial effect of the materials described herein.

[0042] Volatile particles In some embodiments, the aerosol-forming material comprises particles incorporating a volatile component.

[0043] In some embodiments, the volatile component particles consist essentially of particles of the volatile component in solid form. For example, the particles may include particles of menthol or other volatile components that may be solid at room temperature. In other embodiments, the particles may include a carrier material and the volatile component deposited in solid form on or in the carrier material.

[0044] In some embodiments, the volatile component comprises, consists essentially of, or consists of menthol. For example, the aerosol-forming material may include particles of menthol.

[0045] In some embodiments, particles of the solid volatile component are distributed within the aerosol-generating material. In some embodiments, these particles are generally homogeneously distributed within the material. In other embodiments, the distribution of particles of the volatile component is not homogeneous and is designed to result in release of the volatile component at a predetermined time during heating of the aerosol-generating material.

[0046] In some embodiments, the particles of the volatile component have an average particle size of about 0.1 to about 3 mm as determined by sieving. In some embodiments, the use of smaller particles of the volatile component is preferred, for example, the average particle size may be about 0.1 to about 1 mm, or about 0.5 mm to about 2 mm as determined by sieving.

[0047] active substance As used herein, an active substance may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, nutraceuticals, nootropics, psychotropic drugs. The active substance may be of natural origin or synthetically obtained. The active substance may be composed of, for example, nicotine, caffeine, taurine, theine, vitamins, such as B6 or B12 or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or other plants.

[0048] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0049] As referred to herein, an active substance may include or be derived from one or more botanical substances or components, derivatives or extracts thereof. As used herein, the term "botanical substance" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fiber, stems, roots, seeds, flowers, fruits, pollen, husks, pods, and the like. Alternatively, the material may include synthetically derived active compounds naturally occurring in the botanical substance. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, strips, strips, sheets, and the like. Exemplary botanical substances include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo (ginkgo biloba), and the like. biloba), hazel, hibiscus, bay leaf, licorice (liquorice), matcha, yerba mate, orange peel, papaya, rose, sage, tea, e.g. green or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, turmeric, turmeric The preferred oils include walnut, sandalwood, coriander, bergamot, orange blossom, myrtle, blackcurrant, valerian, bell pepper, mace, damien, marjoram, olive, lemon balm, lemon basil, chives, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.Mint includes the following Mint varieties: Mentha arventis, Mentha cv, Mentha niliaca, Mentha piperita, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv and Mentha suaveolens. suaveolens).

[0050] In some embodiments, the active agent may include or be derived from one or more botanical substances or components, derivatives or extracts thereof, and the botanical substance is tobacco.

[0051] In some embodiments, the active agent may include or be derived from one or more botanical substances or components, derivatives or extracts thereof, the botanical substances being selected from eucalyptus, star anise, cocoa and cannabis.

[0052] In some embodiments, the active agent may include or be derived from one or more botanical substances or components, derivatives or extracts thereof, and the botanical substances are selected from rooibos and fennel.

[0053] Particles of active substance In some embodiments, the aerosol-forming material comprises particles that include one or more active agents. Particles of active agents are also referred to herein as "active particles."

[0054] In some embodiments, the active agent is a plant-derived active agent. In such embodiments, the active agent particles may be plant particles that contain the active agent. Alternatively, the active agent particles may include the active agent deposited in or on a carrier material particle.

[0055] In some embodiments, the active substance is nicotine. The nicotine particles may be particles of tobacco material. Alternatively, the nicotine particles may include a carrier material and nicotine.

[0056] In some embodiments, the particles comprising the active agent present in the aerosol-generating material have a size small enough that a plurality of such particles can agglomerate to form an aerosol delivery system having desired dimensions based on its intended use.

[0057] Smaller particles of an active agent have a larger surface area to volume ratio and therefore they may exhibit enhanced release of the active agent compared to larger sized particles.

[0058] Additionally, the size of the active particles (and other particles in the precursor composition) affects the aggregate structure and porosity and density of the particulate aerosol-generating material. Thus, the size of the active particles may be selected to produce a more porous aggregate structure, which affects the release of the active. Thus, the size of the active particles is another factor that can be adjusted to affect the release of the active, especially when the particulate aerosol-generating material has an aggregate structure created by granulation as opposed to extrusion.

[0059] The preferred size of active particles may also depend on the method used to form the aggregate structure. For example, the extrusion process may be sensitive to the size of the particles in the composition to be extruded. Specifically, in some embodiments in which the precursor composition is extruded to form an aggregate structure, it may be desirable for the particles in the precursor composition, including the active particles, to have an average particle size of about 3 mm or less, an average particle size of about 1 mm or less, an average particle size of about 0.5 mm or less, or an average particle size of about 0.3 mm or less, as measured by sieving.

[0060] In some embodiments, it may be desirable for the active particles in the precursor composition and / or in the aerosol-forming material to have an average particle size of about 3 mm or less, about 1 mm or less, about 0.5 mm or less, or about 0.3 mm or less, as measured by sieving. In some embodiments, the average particle size is in the range of about 0.1 to about 3 mm, about 0.1 to about 1 mm, about 0.1 to about 0.5 mm, about 0.1 to about 0.4 mm, or about 0.2 to about 0.3 mm. In some embodiments, at least about 90% of the particles of the precursor composition have a particle size in the range of about 0.1 to about 3 mm, or about 0.1 to about 1 mm, or about 0.1 to about 0.5 mm. In some embodiments, at least about 90% of the active particles of the precursor composition have a particle size in the range of about 0.1 to about 3 mm, or about 0.1 to about 1 mm, or about 0.1 to about 0.5 mm. In some embodiments, none of the particles in the precursor composition have a particle size greater than 5 mm, greater than 4 mm, greater than 2 mm, greater than 1.5 mm, or greater than about 1 mm.

[0061] In some embodiments, the active particles are particles of plant material. When the active substance is or includes nicotine, the active particles may be particles of tobacco material (referred to herein as tobacco particles).

[0062] Particles of the desired size can be formed by grinding, shredding, cutting or crushing plant material, such as tobacco material. Suitable machines for creating such plant particles include, for example, shredders, cutters, or mills, such as hammer mills, roller mills, or other types of commercially available grinders. The size of the plant particles is selected to provide particles that can be readily prepared from a variety of different types of plant material and formed into an agglomerated structure using the processes described herein, have the properties described herein, and provide a source of readily released active substances.

[0063] Without wishing to be bound by any particular theory, it is speculated that shredding tobacco to form tobacco particles enhances the release of tobacco components, including volatile flavor and aroma components, in addition to nicotine. It is also believed that the increased surface area of ​​the tobacco particles enhances volatilization. Smaller tobacco particles also improve the homogeneity of the aggregate structures formed from the tobacco particles with other components.

[0064] The tobacco material used to form the tobacco particles may be any type of tobacco and any part of the tobacco plant, including tobacco flakes, stems, stalks, veins, stubble, and cuttings, or a mixture of two or more thereof. Suitable tobacco materials include the following types: Virginia or flue-cured tobacco, Burley tobacco, Oriental tobacco, or blends of tobacco materials, optionally including those listed herein. The tobacco may be expanded, such as dry ice expanded tobacco (DIET), or processed by any other means. In some embodiments, the tobacco material may be a reconstituted tobacco material. The tobacco may be pre-processed or unprocessed, for example, solid stem (SS); shredded dried stem (SDS); steam-treated stem (STS); or any combination thereof. The tobacco material may be fermented, cured, uncured, toasted, or otherwise pre-processed.

[0065] pH adjustment In some embodiments, the aerosol-generating material is formed from a precursor composition including active particles, where the pH of the active particles is adjusted to a basic pH. For example, the pH may be adjusted to at least about 7.5. The pH may be adjusted by the addition of one or more bases. Alternatively, the pH may be adjusted by the use of a buffer.

[0066] In some embodiments, the aerosol forming material comprises active particles and one or more bases or a basic buffer system such that the active particles have a basic pH, for example, the pH may be at least about 7.5.

[0067] The purpose of adjusting the pH of the active particles and / or precursor compositions is to provide the active substance in a chemical form that is easily released from the aerosol-forming material and / or to facilitate easy transfer of the active substance into the aerosol generated by the smoking article.

[0068] In some embodiments, the pH of the active particles is adjusted to at least about 7.5, at least about 8, at least about 8.5, at least about 9, at least about 9.5, or at least about 10. In some embodiments, the pH is adjusted to about 14 or less, about 13.5 or less, about 13 or less, about 12.5 or less, about 12 or less, about 11.5 or less, about 11 or less, about 10.5 or less, or about 10 or less. In some embodiments, the pH of the active particles is adjusted to about 8 to about 10, or about 8.5 to about 9.5.

[0069] In some embodiments, the pH of the aerosol-forming material is at least about 7.5, at least about 8, at least about 8.5, at least about 9, at least about 9.5, or at least about 10. In some embodiments, the pH is about 14 or less, about 13.5 or less, about 13 or less, about 12.5 or less, about 12 or less, about 11.5 or less, about 11 or less, about 10.5 or less, or about 10 or less. In some embodiments, the pH of the aerosol-forming material is adjusted to between about 8 and about 10, or between about 8.5 and about 9.5.

[0070] In some embodiments, the pH of the aerosol-forming material is adjusted to about 7.5 to about 10, or about 8 to about 9, or about 8.5, about 9, about 9.5, or about 10.

[0071] In some embodiments, the base used to adjust the pH is a hydroxide or carbonate. The hydroxide used may be a mono-, di- or tri-acid base. Suitable bases include, for example, potassium hydroxide, calcium hydroxide, silver hydroxide, ammonium hydroxide, magnesium hydroxide, sodium carbonate, sodium bicarbonate (also known as sodium hydrogen carbonate), and potassium carbonate.

[0072] The base may be added in liquid form, such as an aqueous or non-aqueous solution or suspension, or in solid form, such as a powder.

[0073] In some embodiments, the pH of the particles that include a volatile component is not adjusted.

[0074] In some embodiments, the aerosol-generating material is formed from a precursor composition comprising a mixture of particles incorporating a volatile component and particles comprising an active agent. In some embodiments, the precursor composition further comprises a pH adjuster. In embodiments in which the volatile component particles, active particles and pH adjuster are dry, for example when the base is in the form of a dry powder, the pH of the precursor composition will be adjusted (compared to the pH of the particles without the pH adjuster) when water is added to the composition.

[0075] As used herein, the pH of a precursor composition or aerosol-forming material refers to the pH after water has been added to the composition or material if the composition or material is dry.

[0076] In some embodiments, the buffer system used to adjust the pH is a mixture of a weak base and its conjugate acid. Suitable buffer systems include, for example, those having a pH of at least about 7.5, at least about 8, at least about 8.5, or at least about 9. In some embodiments, the pH of the buffer system is about 8 to about 10, or about 8.5 to about 9.5. Suitable buffer systems include, for example, those based on ammonia, carbonate, or hydroxide with appropriate counterions. An example of a particular buffer system is a mixture of ammonia and ammonium chloride.

[0077] Additional components of aerosol-generating materials In some embodiments, the aerosol-forming material having an aggregate structure is formed from a precursor composition that includes active particles and volatile component particles.

[0078] In some embodiments, the precursor composition and / or the aerosol-forming material does not include a binder or binding additive. In other embodiments, the precursor composition includes a binder or binding additive. The binding additive may be selected to aid in the formation of a cohesive structure by helping to adhere the particles to each other and to other components in the aerosol-forming material. Suitable binding additives include, for example, thermoreversible gelling agents such as gelatin, starch, polysaccharides, pectin, alginates, wood pulp, cellulose, and cellulose derivatives such as carboxymethylcellulose.

[0079] In some embodiments, the precursor composition and / or aerosol forming material further comprises a diluent. The diluent may be in solid or liquid form. In some embodiments, the diluent is inert or substantially inert.

[0080] In some embodiments, the aggregate structure formed from the precursor composition may have an increased surface area by including particles of an inert filler in the precursor composition. Suitable inert fillers may be porous or non-porous.

[0081] In some embodiments, the precursor composition and / or aerosol-generating material further comprises at least one aerosol-forming agent, which may be, for example, a polyol aerosol-forming agent or a non-polyol aerosol-forming agent, preferably a non-polyol aerosol-forming agent. The aerosol-forming agent may be a solid or liquid at room temperature, but is preferably a liquid at room temperature. Suitable polyols include sorbitol, glycerol, and glycols such as propylene glycol or triethylene glycol. Suitable non-polyols include monohydric alcohols, high boiling point hydrocarbons, acids such as lactic acid, and esters such as diacetin, triacetin, triethyl citrate, or isopropyl myristate. The aerosol-forming agents may be used in combination in equal or different proportions. Glycerol and propylene glycol may be particularly preferred.

[0082] In some embodiments, the precursor composition and / or aerosol-forming material may include a flavor modifier to modify the flavor provided by the tobacco particles or to add flavor. In some embodiments, the flavor modifier may be included in the precursor composition. Alternatively or additionally, the flavor modifier may be added or applied to the aggregate structure. As used herein, the terms "flavor" and "flavoring agent" refer to materials that may be used to create a desired taste, aroma, or other somatic sensation in products intended for adult consumers, as permitted by local regulations.Fragrances and flavorings include naturally occurring flavor materials, botanical substances, extracts of botanical substances, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, liquorice (licorice), hydrangea, eugenol, magnolia, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese peppermint, aniseed (aniseed), cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherries, berries, red berries, cranberries, peaches, apples, oranges, mangoes, clementines, lemons, limes, Tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberries, mulberries, 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, i Lang ylang, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, cannabis, mint oil of any species of Mentha genus, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, yerba mate, orange peel, rose, tea, e.g. green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, perilla, turmeric, coriander, myrtle, blackcurrant, valerian, bell pepper, nutmeg flower , damien, marjoram, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter receptor site blockers, organoleptic site activators or stimulants, sugar and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners.These may be imitation, synthetic, natural or blends thereof. The fragrances and flavourings may be in any suitable form, for example liquids such as oils, solids such as powders, or gases.

[0083] In some embodiments, the flavoring comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavoring comprises cucumber, blueberry, citrus fruit, and / or red berry flavor ingredients. In some embodiments, the flavoring comprises eugenol. In some embodiments, the flavoring comprises flavor ingredients extracted from tobacco. In some embodiments, the flavoring comprises flavor ingredients extracted from cannabis.

[0084] In some embodiments, the flavoring may include a sensate that is intended to achieve somatic sensations, usually chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or instead of aroma or taste sensations, and may include agents that produce a heating, cooling, tingling, or numbing effect. A suitable warming agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucolyptol, WS-3.

[0085] In some embodiments, the precursor composition and / or aerosol-forming material further comprises a preservative. Suitable preservatives will be familiar to those skilled in the art and will include, for example, those that are safe for use in products that generate inhalable aerosols. Examples of preservatives that may be used include propylene glycol, carvacrol, thymol, L-menthol, 1,8-cineole, phenoxyethanol, herbicides, sorbic acid and its salts, sodium hydroxymethylglycinate, ethylhexylglycerin, parabens, and vitamins, such as vitamin E or vitamin C.

[0086] In some embodiments, neither the precursor composition nor the aerosol forming material comprises a gelling agent.

[0087] Morphology of aggregate structure In some embodiments, the aerosol-forming material is in granular form and is small, discrete particles, In most embodiments, multiple particles will be incorporated into the device to provide the desired effect on the aerosol of the device.

[0088] In some embodiments, the particulate aerosol-forming material has an average size (as measured by sieving) of about 0.5 mm to about 4 mm. In some embodiments, it may be preferred that the granules have an average size of about 0.7 mm to about 3 mm.

[0089] In other embodiments, the aerosol-generating material is in the form of a monolith that is a larger item. In most embodiments, a single monolithic component will be incorporated into the device to have the desired effect on the aerosol of the device.

[0090] In some embodiments, the monolith components are approximately spherical or cylindrical in shape. The monolith components may have a diameter of about 4 mm to about 10 mm. In some embodiments, the diameter may be about 5 mm to about 8 mm. The cylindrical components may additionally have a length of about 5 mm to about 80 mm, about 15 mm to about 50 mm, or about 20 mm to about 30 mm.

[0091] Formation of aggregate structures FIG. 1 is a flow chart showing the main steps in the process of some embodiments of the present invention. Tobacco starting material, which may be pretreated or preprocessed, is ground to a desired particle size. The pH is adjusted by adding one or more bases or by adding a buffer solution to the tobacco particles. Particles of a volatile component are added to the tobacco particles to form a precursor material. Optional additional components may be added to the precursor material. These additional components may be in liquid or solid form. Additional solid components are preferably in granular or powder form. Additional components may be added before, during, or after the pH adjustment step. An aggregate structure is then formed from the resulting precursor composition by adhering the pH-adjusted tobacco particles and any other components to form a multiparticulate entity.

[0092] In some embodiments, water may be added to the precursor composition as a processing aid. For example, the presence of water can aid in dissolving components of the precursor composition, such as pH adjusters and sugars, and / or aid in binding or improve cohesion.

[0093] In some embodiments, the aggregate structure may be formed from the precursor composition by a process comprising one or more steps selected from the group consisting of granulation, extrusion, and spheronization.

[0094] Granulation Granulation of the precursor composition involves bonding or fusing particles of the precursor composition together to form larger multiparticulate entities, which are referred to herein as agglomerated structures. The multiparticulate entities formed by granulation are referred to as granules, which may have a variety of geometric shapes, including the common forms of, for example, spheres, cylinders, etc.

[0095] In one embodiment, the granulation process used is wet granulation. In wet granulation, a granulation liquid is added onto a powder bed to form granules. Agitation in the system causes agglomeration of particles along with wetting of the ingredients in the precursor composition to produce wet granules. The granulation liquid is at least partially removed by drying to obtain dry granules. The granulation liquid may be aqueous or solvent-based. Suitable granulation liquids include, for example, water, glycerol, ethanol, and isopropanol, alone or in combination. In some embodiments, the granulation liquid includes an aerosol-forming agent, such as glycerol or one of the other agents described herein, and / or a binding agent or binder. In some embodiments, water is not added to the precursor composition to aid in granulation.

[0096] In another embodiment, the granulation process used is dry granulation. In dry granulation, granules are formed without the use of granulation liquid. This type of process has the advantage that the precursor composition is not exposed to moisture, and therefore does not need to be exposed to heat to dry the granules. To form granules in dry granulation, the precursor composition usually needs to be compressed under high pressure to densify.

[0097] Extrusion Extrusion of the precursor composition involves feeding the precursor composition through an orifice to produce an extruded mass, the process subjecting the precursor composition to pressure and shear forces to produce a cohesive structure.

[0098] Extrusion can be carried out using one of the major classes of extruders: screw, screen and basket, roll, ram, and pin barrel extruders. Single or twin screw extruders may be used. Shaping the aerosol-generating material by extrusion has the advantage that this process combines mixing, conditioning, homogenization, and shaping of the precursor composition.

[0099] In some embodiments, during extrusion, the free-flowing precursor composition is subjected to elevated pressure and temperature and forced through an orifice, such as a shaped nozzle or die, to form an extruded mass. In some embodiments, the extruded mass may have a rod-like form and / or may be cut into segments of desired length upon exiting the orifice. The rod-like extruded mass can then be cut into segments of desired length.

[0100] In some embodiments, the precursor composition is exposed to a temperature of about 40° C. to about 150° C., or about 80° C. to about 130° C., or about 60° C. to about 95° C. in the extruder. In some embodiments, including those using dual extrusion, the precursor composition is exposed to a temperature of about 70° C. to about 95° C. in the extruder. In some embodiments, including those using single extrusion, the precursor composition is exposed to a temperature of about 60° C. to about 80° C. in the extruder. The composition may be exposed to a pressure (just before the die or nozzle) ranging from about 2 bar to about 100 bar, or from about 5 bar to about 60 bar, depending on the design of the die or nozzle used.

[0101] In some embodiments, when the active particles are particles of plant material such as tobacco, due to the relatively high density of the extruded mass and the relatively open surfaces of the plant particles therein, the aerosol-forming material formed from the extruded mass exhibits good heat and mass transfer, which favorably affects the release of the active material and volatile components.

[0102] In some embodiments, extrusion may be a generally dry process, and the precursor composition is a dry or substantially dry material that includes active particles, volatile component particles, and optionally other particulate materials including, for example, bases, diluents, solid aerosol formers, solid flavor modifiers, and the like.

[0103] In some embodiments, a liquid may be added to the precursor composition during the extrusion process. For example, water may be added to the precursor composition as a processing aid, for example to aid in dissolving or solubilizing the components of the composition, or to aid in binding or cohesion. Alternatively or additionally, a wetting agent may be added to the precursor composition.

[0104] In some embodiments, the liquid may be an aerosol-forming agent, such as glycerol or others discussed herein. Adding a liquid to the precursor composition in this manner not only applies the liquid to the surface, but as a result of the extruder pressure combined with intensive mixing due to high shear forces, the extruded mass becomes impregnated with the liquid. If the liquid is an aerosol-forming agent, this can result in a high utilization rate of the aerosol-forming agent in the agglomerated product to promote evaporation and release of the active agent and other volatile components from the agglomerated structure.

[0105] In some embodiments, in view of the impregnation of the extruded mass with the aerosol-forming agent, a larger amount of this additive can be incorporated into the aerosol-generating material than if the aerosol-forming agent were simply applied to the surface of the precursor composition or extruded aggregate. In some embodiments, the amount of the aerosol-forming agent incorporated into the aerosol-generating material may be at least about 1% by weight, at least about 1.5% by weight, at least about 2% by weight, at least about 3% by weight, at least about 5% by weight, at least about 10% by weight, at least about 15% by weight, or at least about 20% by weight. In some embodiments, the amount of the aerosol-forming agent incorporated into the aerosol-generating material may be up to about 30% by weight, or even up to about 40% by weight. If the aerosol-generating material generates an aerosol in addition to releasing an active substance and a volatile component, a larger amount of the aerosol-forming agent, such as at least about 10% by weight or at least about 20% by weight, may be advantageous. If the primary function of the aerosol-generating material is to release the active substance and a volatile component carried by the material into an existing aerosol or air stream, a smaller amount of the aerosol-forming agent, such as up to about 5% by weight, may be sufficient.

[0106] The extruded mass is formed by a nozzle or die through which the extruded mass is passed. In some embodiments, the extruded mass is cut into pieces of a desired length. The pieces so formed may be used as aerosol generating material or may be subjected to further processing.

[0107] In some embodiments, a nozzle or die is formed to provide a solid strand of extruded mass. For example, the extruded mass may have the form of a solid cylindrical rod. Alternatively, the extruded mass may have a variety of cross-sectional shapes, including ovals, polygons (e.g., triangles, squares, etc.), and stars.

[0108] In some embodiments, the extruded composition is molded into a desired shape selected to enhance or promote the release of the active and volatile components, for example by providing a mold with a large surface area per unit volume. This large surface area can be imparted to the outer surface of the extruded mass, for example by selecting a cross-sectional shape with a large circumference. Alternatively or additionally, the large surface area can be achieved by creating grooves within the extruded mass.

[0109] In some embodiments, the nozzle is shaped to result in an extruded mass with internal grooves that provide additional surface area and can enhance the release of components.

[0110] The aerosol-generating material formed from the so-shaped extruded mass sections has an internal grooved structure with advantageously tunable strand ventilation properties and has a significantly expanded internal surface resulting in improved heat and mass transfer. As a result, such shaped materials exhibit better and more homogeneous release of active substances and volatile components by evaporation. Furthermore, the internal grooved structure exhibits greatly improved strength in both the radial and axial directions, which is beneficial for further processing of the extruded mass, for example, when the extruded mass is cut into multiple sections.

[0111] Various nozzle or die designs and / or different process parameters within the extruder, such as temperature, pressure, shear force, etc., can prepare extruded masses with different physical properties, including different heat transfer characteristics, draft resistance, allowing for the generation of different aerosols and / or modification of the aerosol drawn through the extruded mass.

[0112] In some embodiments, the extruded mass is shaped upon exiting the extruder. In some embodiments, the extruded mass can be cut to an initial length, for example, of one meter, and cut into sections of desired length after cooling to provide the aerosol-generating material in the form of particles of desired dimensions.

[0113] In some embodiments, the extrusion mass may be cooled immediately before or as it exits the extruder. In some embodiments, the cooling is intensive and includes exposing the extrusion mass at an elevated temperature, for example, from about 30°C to about 100°C, or from about 40°C to about 70°C, to a cooling means that reduces the temperature to within the range of about 0°C to about 70°C, about 0°C to about 50°C, about 5°C to about 25°C, or about 5°C to about 15°C. This rapid cooling of the extrusion mass can improve the internal and external stability of the extrusion mass. In some embodiments, it is the nozzle or die that is cooled to achieve this effect.

[0114] In some embodiments, it may be desirable to control the temperature of the precursor composition during extrusion, including before feeding the composition through a nozzle or die. This is particularly true when the precursor composition includes a temperature-sensitive component, such as an aerosol former, for example, glycerol. Thus, in some embodiments, extrusion of the precursor composition includes reducing the temperature of the precursor composition before it reaches the nozzle or die. Such cooling of the precursor composition may result in the formation of an extruded mass with beneficial properties, or may improve the strand forming process, for example, if channels are to be formed within the extruded aggregate strands.

[0115] In some embodiments, spheronization is used to further process the extruded segments. These sections are typically cylindrical and are cut or broken into uniform lengths after extrusion. These sections are then gradually transformed into spheres by spheronization. This shaping occurs as a result of plastic deformation, and spheronization results in spherical aggregate structures with approximately uniform diameters.

[0116] Installation in equipment One or more particles of the aerosol-generating material may be incorporated into an aerosol delivery system, such as an apparatus for heating the aerosol-generating material to volatilize at least one component of the aerosol-generating material. The aerosol-generating material provided in the aerosol delivery system may comprise, consist essentially of, or consist of the aerosol-generating materials described herein. In some embodiments, the aerosol-generating material used in the aerosol delivery system further comprises one or more other aerosol-generating materials, such as a tobacco material.

[0117] As used herein, aerosol delivery systems include non-combustion aerosol delivery systems that release compounds from an aerosol-forming material without combusting the aerosol-forming material, such as a tobacco heating product, and hybrid systems for generating aerosol using a combination of aerosol-forming materials.

[0118] According to the present disclosure, a "non-combustible" aerosol delivery system is one in which the component aerosol-generating materials (or components thereof) of the aerosol delivery system are not combusted or burned to facilitate delivery of at least one substance to a user.

[0119] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0120] In some embodiments, the non-combustible aerosol delivery system is an e-cigarette, also known as a vape device or an electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0121] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a thermal non-combustion system. One example of such a system is a tobacco heating system.

[0122] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates an aerosol using a combination of aerosol-generating materials, where one or more of the aerosol-generating materials may be heated. Each of the aerosol-generating materials may be, for example, in solid, liquid, or gel form and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or a non-tobacco product.

[0123] Typically, a non-combustion aerosol delivery system may include a non-combustion aerosol delivery device and a consumable for use with the non-combustion aerosol delivery device.

[0124] In some embodiments, the present disclosure relates to consumables that include aerosol generating materials and are configured for use with non-combustible aerosol delivery devices. These consumables may be referred to as articles throughout this disclosure.

[0125] In some embodiments, a non-combustion aerosol delivery system, such as a non-combustion aerosol delivery device, may include a power source and a controller. The power source may be, for example, an electrical power source or a heat generating power source. In some embodiments, the heat generating power source includes a carbon substrate that may be energized to deliver power in the form of heat to an aerosol generating material or a heat transfer material in proximity to the heat generating power source.

[0126] In some embodiments, the non-combustible aerosol delivery system may include an area for receiving a consumable, an aerosol generator, an aerosol-generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0127] In some embodiments, consumables for use with the non-combustible aerosol delivery device may include an aerosol generating material, an aerosol generating material storage area, an aerosol generating material transfer component, an aerosol generating device, an aerosol generating area, a housing, a packaging material, a filter, a mouthpiece, and / or an aerosol modifier.

[0128] The aerosol-generating material may be disposed within the apparatus or device such that the released nicotine and volatile components are entrained in the aerosol generated by the apparatus or device in use and modify the properties of the aerosol. Additionally or alternatively, the aerosol-generating material may itself generate an aerosol in use, said aerosol comprising the released nicotine and volatile components.

[0129] According to some embodiments, one or more particles of the aerosol-forming material are provided in an aerosol delivery system that volatilizes components of the aerosol-forming material by heating but not combusting the material (i.e., tobacco heating products or so-called non-combustion heating products). In some of these products, the aerosol-forming material is heated to generate the aerosol.

[0130] In some embodiments, one or more particles of aerosol-generating material are heated by such products. In some embodiments, one or more particles of aerosol-generating material may be incorporated into a tobacco material to form a material to be heated. For example, one or more particles of aerosol-generating material may be dispersed within a tobacco material, such as cut tobacco or reconstituted tobacco, to contribute the nicotine and flavor imparted by the tobacco. In other embodiments, the tobacco included in the material to be heated by the tobacco heating system consists of or consists essentially of one or more particles of aerosol-generating material. The aerosol-generating material may be heated directly. When the aerosol-generating material is a plurality of particles of aerosol-generating material, these particles may be held in a container or cartridge. At least a portion of the container or cartridge may be permeable to air so that air can flow over or through the particles of aerosol-generating material.

[0131] Figure 3 is a cross-sectional view of an example of a tobacco heating product for heating an aerosol-forming material. The device 11 has a heating chamber 14 that contains the aerosol-forming material which is heated and volatilized in use. In this embodiment, the aerosol-forming material is in the form of a monolithic aerosol-forming material 13. However, the aerosol-forming material could be a plurality of particles of aerosol-forming material held in the heating chamber, or provided in a cartridge such as the one illustrated in Figure 5.

[0132] The device 11 of FIG. 3 further includes an electronics / power compartment 16 that may include, for example, an electrical control circuit and / or a power source (not shown). The electrical control circuit may include a controller, such as a microprocessor arrangement, constructed and arranged to control the heating of the aerosol generating material via a heating element (not shown). The electrical control circuit may receive a signal from a puff-activated sensor that senses a change in pressure or airflow rate that occurs in use, for example, upon initiation of a user's retraction of the device 11. The electrical control circuit may then operate to cause heating of the aerosol generating material "on demand." Various arrangements for the puff sensor are available, including, for example, thermistors, electromechanical devices, mechanical devices, optical devices, opto-mechanical devices, and microelectromechanical systems (MEMS)-based sensors. Alternatively, the device may include a manually operable switch for a user to initiate a puff.

[0133] The heating chamber 14 is contained within a housing 12. To ensure that the housing 12 does not heat up during use, or at least is not too hot to touch, there may be support and / or insulation means (not shown) disposed between the heating chamber 14 and the housing 12, e.g. to help thermally insulate the housing 12 from the heating chamber 14.

[0134] Housing 12 includes an inlet 15 through which air is drawn into the device. Housing 12 also includes an outlet 17 at a mouthpiece 18 of device 11. Air is drawn into device 11 through inlet 15 and travels through the device picking up the active agent and other volatile components released by aerosol-forming material 13, and the resulting aerosol generated by device 11 leaves device 11 through outlet 19 and is inhaled by the user.

[0135] According to some embodiments, one or more particles of the aerosol-generating material are provided in a so-called hybrid system for heating the aerosol-generating material to volatilize at least one component of the aerosol-generating material. In some of these products, in addition to heating the aerosol-generating material to generate an aerosol, a liquid, such as a nicotine-containing or non-nicotine-containing liquid, is heated with a heat source to form an aerosol or vapor. In some hybrid systems, the aerosol or vapor formed from the liquid is drawn over or through the aerosol-generating material, entraining the active substance and other volatile components. In other embodiments, the aerosol or vapor formed from the liquid is not drawn over or through the aerosol-generating material.

[0136] In some embodiments of the hybrid system, the material to be heated includes an aerosol-generating material and a tobacco material, such as cut tobacco. In some embodiments, one or more particles of the aerosol-generating material may be incorporated into the tobacco. For example, one or more particles of the aerosol-generating material may be dispersed within a tobacco material, such as cut tobacco or reconstituted tobacco, and contribute flavor and nicotine imparted by the tobacco. In other embodiments, the aerosol-generating material of the hybrid system includes particles of the aerosol-generating material.

[0137] Figure 4 is a cross-sectional view of one example of a hybrid product for heating an aerosol-generating material and a liquid. The device 21 has a housing 22 including a chamber 24 that contains an aerosol-generating material to be heated and vaporized in use. In this embodiment, the aerosol-generating material is in the form of a monolithic aerosol-generating material 23. However, the aerosol-generating material could be a plurality of particles of the aerosol-generating material held in the chamber or provided in a cartridge such as the one illustrated in Figure 5. The housing 22 also includes a liquid reservoir 25 that contains a liquid 26 to be heated to form a vapor.

[0138] Device 21 further includes an electronics / power compartment 27 that may include, for example, electrical control circuitry and / or a power source (not shown). The electrical control circuitry may include a controller, such as a microprocessor arrangement, constructed and arranged to control the heating of the aerosol generating material and liquid 26 via one or more heating elements (not shown). The electrical control circuitry may puff-activate device 21 to cause heating of the aerosol generating material "on demand." Alternatively, device 22 may include a manually operable switch for a user to initiate a puff.

[0139] The housing 22 also includes an inlet 28 through which air is drawn into the device. The housing 22 also includes an outlet 29 at a mouthpiece 30 of the device 21. Air is drawn into the device 21 through the inlet 28 and travels through the device picking up vapor produced by heating the liquid 26 in the liquid reservoir 25 and the active substance and volatile components released by the aerosol-generating material 23, and the aerosol produced by the device 21 leaves the device 21 through outlet 29 and is inhaled by the user.

[0140] The hybrid device 21 shown diagrammatically in Figure 4 represents just one possible configuration of such an apparatus. The relative positions of the liquid reservoir 25 and the aerosol-generating material chamber 24 can be varied, as can the path of air flow through the apparatus.

[0141] In one embodiment, the liquid reservoir is located upstream of the aerosol-generating material to be volatilized. Alternatively, the liquid reservoir may be located downstream of the aerosol-generating material to be volatilized. In yet another arrangement, two aerosol-generating sources in the device may be positioned side-by-side, etc.

[0142] In some embodiments, the vapor generated by heating the liquid in the liquid reservoir flows over or through the aerosol-generating material, which may include or consist of one or more aerosol-generating materials. In some embodiments, the increase in temperature of the vapor releases the active substance and volatile components. Alternatively or additionally, the smoke aerosol-generating material may be separately heated by a heating means.

[0143] In some embodiments, a hybrid device is provided in which the vapor generated by heating a liquid heats the aerosol-generating material to volatilize at least one component of the aerosol-generating material. In some embodiments, the liquid is a liquid that does not contain nicotine. In other embodiments, the liquid contains nicotine. When the aerosol-generating material is heated by the vapor to volatilize at least one component of the aerosol-generating material, in certain embodiments, the device does not include a separate means for heating the aerosol-generating material.

[0144] In other embodiments, the vapor generated by heating the liquid in the liquid reservoir does not flow over or through the aerosol-forming material, but rather the vapor and the aerosol generated by heating the aerosol-forming material mix only after the two are formed.

[0145] The tobacco heating products and hybrid products described herein may, in some embodiments, include aerosol-generating material in the form of a container or cartridge that contains the aerosol-generating material. These containers or cartridges may be removable. These containers or cartridges may replace both the chamber that holds the aerosol-generating material and the aerosol-generating material in the devices described above with reference to Figures 3 and 4, and in the alternative embodiments discussed.

[0146] Referring to Figure 5, a tobacco segment cartridge 31 is shown and includes a housing 32 defining a cavity in which one or more particles of aerosol-generating material (not shown) are retained. The housing 32 may be made, for example, from molded plastic or the like. An air vent 33 is provided in the housing 32 of the cartridge 31 to allow air drawn through the device to enter the cartridge 31, pass over the one or more particles of aerosol-generating material, and then exit the cartridge 31. In some embodiments, the cartridge 31 may further include heating means, heatable by suitable means, to heat the one or more particles of aerosol-generating material retained therein. EXAMPLES

[0147] In this experiment, menthol was used as the volatile component in solid particulate form. Menthol in powder form was added to the feedstock before extrusion.

[0148] In addition to the menthol particles, the feedstock contained ground tobacco particles, sodium carbonate (Na2CO3), carboxymethylcellulose (CMC) and water. The pH of the feedstock used was 8.5 for each sample prepared. The amount of menthol added was 0% (control composition), 5% and 10% by weight.

[0149] During the extrusion process, the menthol particles were structurally incorporated into the extruded tobacco granule material. The homogeneous mixing of the feedstock containing the menthol particles resulted in the menthol particles being homogeneously distributed throughout the extruded composition. After extrusion, the extrudate was cut into granules.

[0150] The performance of the mentholated extruded granules was tested to evaluate the effect of incorporating menthol into the composition when the granules were incorporated into a hybrid device.

[0151] The hybrid device contained extruded granules as the aerosol generating material and a surrogate (non-flavored) liquid to form the aerosol, which was used to allow accurate detection of the components released from the granules into the aerosol.

[0152] Data generated using mentholated granules is summarized in the table below.

[0153] [Table 1]

[0154] The various embodiments described herein are presented only to aid in the understanding and teaching of the claimed features. These embodiments are provided only as a representative sample of embodiments and are not exhaustive and / or exclusive. The advantages, embodiments, examples, features, features, structures, and / or other aspects described herein should not be considered as limitations on the scope of the invention defined by the claims or limitations of equivalents to the claims, and it will be understood that other embodiments may be utilized and changes may be made without departing from the scope of the invention as claimed. Various embodiments of the invention may suitably include, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. Furthermore, the present disclosure may include other inventions not currently claimed but which may be claimed in the future.

[0155] The delivery systems described herein may be implemented as combustible aerosol delivery systems, non-combustible aerosol delivery systems, or aerosol-free delivery systems.

Claims

1. An aerosol-generating material comprising at least one particle having a volatile component incorporated in a solid form within a composition and at least one particle comprising an active substance, wherein the volatile component has a vapor pressure at 20°C that is equal to or greater than the vapor pressure of the active substance at 20°C, and wherein release of the active substance from the aerosol-generating material is controlled by competition with release of the volatile component.

2. 13. The aerosol generating material of claim 1 for inclusion in an aerosol delivery system.

3. 3. The aerosol-forming material of claim 1 or 2, wherein the active substance is nicotine.

4. The aerosol-forming material of any one of claims 1 to 3, wherein the particles containing the active substance are tobacco particles.

5. 5. The aerosol-forming material of claim 1, wherein the volatile component has a vapor pressure of at least 6 Pa at 20° C.

6. The aerosol-forming material of any one of claims 1 to 5, wherein the volatile component is a volatile fragrance.

7. 7. The aerosol forming material of claim 6, wherein the volatile component is selected from the group consisting of menthol, limonene, linalool, camphene and eucalyptol.

8. 6. The aerosol-forming material of claim 1, wherein the volatile component has no inherent or characteristic fragrance.

9. 9. The aerosol-forming material according to claim 1, wherein the pH of the aerosol-forming material is from about 4 to about 9.

5.

10. 10. The aerosol generating material of claim 9, wherein the pH of the aerosol generating material is increased by the addition of one or more bases or a basic buffer system.

11. 11. The aerosol generating material of claim 10, wherein the one or more bases are selected from the group consisting of hydroxides, carbonates, and bicarbonates, and optionally the one or more bases are selected from the group consisting of potassium hydroxide, sodium hydroxide, sodium carbonate, and sodium bicarbonate.

12. 12. The aerosol-forming material of any one of the preceding claims, wherein the particles comprising the active agent have an average diameter of 3 mm or less, 1 mm or less, 0.5 mm or less, or 0.3 mm or less.

13. 13. The aerosol-forming material of claim 1, wherein the particles incorporating a volatile component are particles consisting of the volatile component.

14. 14. The aerosol-forming material of any one of the preceding claims, wherein the particles incorporating a volatile component have an average diameter of 3 mm or less, 1 mm or less, 0.5 mm or less, or 0.3 mm or less.

15. 15. The aerosol-generating material of any one of claims 1 to 14, further comprising one or more aerosol forming agents.

16. 16. The aerosol generating material of claim 15, wherein the aerosol forming agent is selected from the group consisting of glycerol, propylene glycol, and glyceryl triacetate.

17. The aerosol-forming material of any one of claims 1 to 16, further comprising one or more binders.

18. 18. The aerosol-forming material of claim 17, wherein the one or more binders are selected from the group consisting of thermoreversible gelling agents, such as gelatin; starch; polysaccharides; pectin; cellulose; cellulose derivatives, such as carboxymethylcellulose; and alginates.

19. 19. The aerosol-forming material of any one of claims 1 to 18, wherein a precursor composition comprising the volatile component particles and the particles comprising an active agent is granulated or spheronized to form an aggregate structure.

20. 20. The aerosol-forming material of any one of claims 1 to 19, wherein a precursor composition comprising particles of the volatile component and the particles comprising an active agent is extruded to form an aggregate structure.

21. The aerosol-forming material of any one of claims 1 to 20, in the form of granules.

22. An aerosol delivery system comprising an aerosol-forming material according to any one of claims 1 to 21.

23. 3. The system of claim 2, wherein the system is an aerosol-generating material heating system comprising an aerosol-generating material that is heated to volatilize a volatile component, and optionally comprising a filter or filter element.

24. 23. The system of claim 22, wherein the system is a hybrid system comprising an aerosol generating material that is heated to volatilize components and a liquid that is heated to form a vapor, and optionally a filter or filter element.

25. 23. The system of claim 22, wherein the aerosol-forming material is heated by steam.

26. 26. The system of claim 25, wherein the liquid is a nicotine-free liquid.

27. 27. The system of claim 25 or 26, wherein the device comprises means for heating the liquid to form a vapor but does not comprise separate means for heating the aerosol forming material.

28. 1. A method for preparing an aerosol-generating material comprising a volatile component for use in an aerosol delivery system, the method comprising the step of incorporating the volatile component into a composition in solid form, the volatile component having a vapor pressure at 20°C that is equal to or greater than the vapor pressure of the active substance at 20°C.

29. 30. The method of claim 28, wherein the aerosol-forming material is formed from a precursor composition comprising particles including the volatile component and particles including an active agent.

30. 30. The method of claim 29, wherein the precursor composition is granulated or spheronized to form an aggregate structure.

31. The method of claim 29 , wherein the precursor composition is extruded to form a coherent structure.

32. 22. An apparatus for heating an aerosol generating material to volatilize at least one component of the aerosol generating material and a nicotine-free liquid which is heated to form a vapour, the aerosol generating material comprising the aerosol generating material of any one of claims 1 to 21, and the aerosol generating material is heated by the vapour.

33. 33. The apparatus of claim 32, comprising a means for heating the liquid to form a vapor, but not a separate means for heating the aerosol forming material.

34. 23. The device of claim 32 or 22, wherein the pH is increased by the addition of one or more bases or a basic buffer system.

35. 1. A particle incorporating a volatile component in solid form for use in controlling the release of nicotine in an aerosol-forming material, the volatile component having a vapor pressure at 20°C that is equal to or greater than the vapor pressure of the active substance at 20°C.

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