Method of manufacturing pre-vapor formulation including volatile components

Abstract

To provide a method of extracting volatile components from a tobacco material and a method of making a pre-vapor formulation including the volatile components.SOLUTION: A method of extracting volatile components from a tobacco material and a method of making a pre-vapor formulation including the volatile components include heating (100) a tobacco material to release volatile components, collecting (200) the extracted volatile components, and combining (300) the volatile components with a pre-vapor formulation.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates to methods of extracting volatile matter from tobacco materials and methods of making pre-vapor formulations containing the extracted volatile matter. [Background technology]

[0002] The electronic vaping device includes a heater element that vaporizes a pre-vapor formulation to produce a vapor, which may include at least one of an aerosol former, water, and flavoring agents. Summary of the Invention

[0003] At least one exemplary embodiment relates to a method of extracting volatile matter from a tobacco material and a method of making a pre-vapor formulation that includes the extracted volatile matter.

[0004] In at least one exemplary embodiment, a method of making a pre-vapor formulation includes heating a tobacco material to a temperature in the range of about 50° C. to about 250° C. to form a heated tobacco material, recovering volatile matter from the heated tobacco material, and combining the volatile matter with the pre-vapor formulation after the recovering step. The step of combining the volatile matter with the pre-vapor formulation is preferably performed immediately after the recovering step. As used herein, the term "immediately" is used to mean combining the recovered volatile matter with the pre-vapor formulation without an intervening step between the recovering step and the combining step.

[0005] In the heating step, the tobacco material is heated to a temperature in the range of about 50°C to about 250°C, preferably about 100°C to about 200°C, and preferably about 125°C to about 175°C.

[0006] The heating step is preferably carried out at standard atmospheric pressure.

[0007] In at least one exemplary embodiment, the method may further include combining an additive with the tobacco material prior to the heating step. The additive may promote the Maillard reaction. The additive may facilitate enzymatic hydrolysis to promote release of flavorants. The additive may include one or more of a casing solution, a solvent, a pH adjuster, and a flavorant. The solvent may include one or more of water, ethanol, glycerin, and propylene glycol.

[0008] In at least one exemplary embodiment, the recovering step can include inserting an adsorbent material into the heated tobacco material, the adsorbent material configured to adsorb the volatiles. The method can also include at least one of desorbing the volatiles from the adsorbent material, disposing the adsorbent material in a reservoir containing the pre-vapor formulation, and disposing the adsorbent material in an e-vaporing device.

[0009] In at least one exemplary embodiment, the recovering step can include condensing the volatiles.

[0010] In at least one exemplary embodiment, the recovering step can include bubbling the volatiles through a solvent trap.

[0011] In at least one exemplary embodiment, the method may also include rotating the tobacco material during the heating step.

[0012] In at least one exemplary embodiment, the tobacco material may be in one of the following forms: a slurry, a moist tobacco mass, and a substantially dry tobacco mass.

[0013] In at least one exemplary embodiment, the method can also include maintaining the pre-vapor formulation at or below room temperature.

[0014] In at least one exemplary embodiment, the method may also include adjusting the pH of the tobacco material prior to the heating step.

[0015] In at least one exemplary embodiment, the tobacco material may be heated for about 2 seconds to about 1 hour, preferably about 2 seconds to about 5 minutes. In at least one exemplary embodiment, the tobacco material may be heated for about 1 second to about 1 hour, preferably about 2 seconds to about 50 minutes, preferably about 5 seconds to about 40 minutes, preferably about 10 seconds to about 30 minutes, preferably about 20 seconds to about 20 minutes. The volatile components are preferably combined with the pre-vapor formulation immediately after collection.

[0016] In at least one exemplary embodiment, the tobacco material may include a mixture of two or more different tobacco varieties.

[0017] Various features and advantages of the non-limiting embodiments herein will become more apparent upon consideration of the detailed description in conjunction with the accompanying drawings. The accompanying drawings are provided for illustrative purposes only and should not be construed as limiting the scope of the claims. The accompanying drawings should not be considered to be drawn to scale unless explicitly noted. For purposes of clarity, various dimensions of the drawings may be exaggerated. [Brief description of the drawings]

[0018] [Figure 1] FIG. 1 is a diagram illustrating an apparatus for extracting tobacco material from volatile matter and for producing a pre-vapor formulation, according to at least one exemplary embodiment. [Diagram 2] FIG. 2 is a flow chart illustrating a method of making a pre-vapor formulation, according to at least one exemplary embodiment. [Diagram 3] FIG. 3 is a flow chart illustrating a heating process according to at least one example embodiment. [Figure 4] FIG. 4 is a flow chart illustrating the recovering and combining steps according to at least one example embodiment. [Diagram 5] FIG. 5 is a flow chart illustrating the recovering and combining steps according to at least one example embodiment. [Figure 6] FIG. 6 is a flowchart illustrating a recovering process in accordance with at least one example embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] Several detailed exemplary embodiments are disclosed herein. However, the specific structural and functional details disclosed herein are merely representative for purposes of describing the exemplary embodiments. However, the exemplary embodiments may be embodied in many alternative forms and should not be construed as being limited to only the exemplary embodiments set forth herein.

[0020] Thus, while exemplary embodiments are susceptible to various modifications and alternative forms, exemplary embodiments have been shown by way of example in the drawings and are described in detail herein. It should be understood, however, that there is no intention to limit the exemplary embodiments to the particular forms disclosed, but on the contrary, the exemplary embodiments are intended to cover all modifications, equivalents, and alternatives falling within the scope of the exemplary embodiments. Like numerals refer to like elements throughout the description of the figures.

[0021] It will be understood that when an element or layer is referred to as "on," "connected to," "coupled to," or "overlying" another element or layer, it can be directly on, directly connected to, directly coupled to, or directly overlying the other element or layer, or there may be intervening elements or layers present. In contrast, when an element is referred to as "directly on," "directly connected to," or "directly coupled to" another element or layer, there are no intervening elements or layers present.

[0022] It should be understood that terms such as first, second, third, etc. may be used herein to describe various elements, components, regions, layers, or sections, but these elements, components, regions, layers, or sections are not limited by these terms. These terms are used only to distinguish one element, component, region, layer, or section from another component, region, layer, or section. Thus, a first element, component, region, layer, or section discussed below can also be referred to as a second element, component, region, layer, or section without departing from the teachings of the exemplary embodiments.

[0023] Spatial relationship terms (e.g., "below," "downward," "lower," "upward," "upper," and the like) may be used herein to facilitate describing the relationship between one element or feature and another element or feature when illustrated in the figures. Of course, the spatial relationship terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, an element described as "below" or "below" the other element or feature would then be oriented "above" the other element or feature. Thus, the term "downward" may encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or in other orientations) and the spatial relationship descriptors used herein interpreted accordingly.

[0024] The terminology used herein is for the purpose of describing various exemplary embodiments only and is not intended to limit the exemplary embodiments. The singular forms "a," "an," and "the," as used herein, are intended to include the plural forms unless the context clearly indicates otherwise. It will be further understood that the terms "includes," "including," "comprises," and "comprising," as used herein, specify the presence of stated features, integers, steps, operations, elements, or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, or groups thereof.

[0025] Exemplary embodiments are described herein with reference to cross-sectional illustrations that are schematic illustrations (and intermediate structures) of idealized embodiments of exemplary embodiments. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques or tolerances, are expected. Thus, exemplary embodiments are not to be construed as limiting the shapes of regions illustrated herein and include deviations in shapes that result, for example, from manufacturing.

[0026] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the exemplary embodiments pertain. It will be further understood that terms (including commonly used dictionary defined terms) should be interpreted to have a meaning consistent with the meaning of those terms in the context of the relevant art, and not to be interpreted in an idealized or overly formal sense, except where expressly so defined herein.

[0027] Electronic vaporizing devices, such as e-cigarettes and e-cigarettes, generate a vapor when a pre-vapor formulation is heated. The vapor may pass through a substrate containing the tobacco material where the vapor leaches volatiles from the tobacco material. In other embodiments, the tobacco material may be heated. The volatiles may be less volatile compounds that tend to remain in the heater, which may cause the heater to decompose at high temperatures and form residues that may degrade the heater's performance.

[0028] At least one exemplary embodiment relates to a method for extracting volatiles from a tobacco material and adding the volatiles to a pre-vapor formulation.At least one exemplary embodiment relates to an apparatus for forming a pre-vapor formulation including the extracted volatiles.

[0029] In at least one exemplary embodiment, the pre-vapor formulation may be a material or combination of materials that can be converted into a vapor. For example, the pre-vapor formulation may include at least one of liquid, solid, and gel formulations, including, but not limited to, water, beads, solvents, active ingredients, ethanol, botanical extracts, natural or artificial flavors, vapor formers such as glycerin and propylene glycol, and combinations thereof. The pre-vapor formulation includes volatiles extracted from tobacco, as described herein.

[0030] FIG. 1 is a diagram illustrating an apparatus for extracting tobacco material from volatile matter and for producing a pre-vapor formulation, according to at least one exemplary embodiment.

[0031] The various figures depict continuous process steps. It should be understood by one skilled in the art that these different steps may involve batch, continuous or semi-batch operations. For example, the treated tobacco mass may be mixed with additives and pressurized at a temperature in a batch type vessel for a period of time before being discharged or purged into a collection vessel. It should also be understood that fermentation or enzymatic processes that may produce tobacco-specific flavorants are included as part of the tobacco flavor creation and isolation process.

[0032] As shown in FIG. 1 , in at least one exemplary embodiment, an apparatus 5 for making a pre-vapor formulation is provided. The apparatus 5 may include a container 12 configured to hold a tobacco material 10. A heat source 14 heats the tobacco material 10 to release volatile matter 20 from the tobacco material 10. The heat source 14 may be an electrical heat source that may be controlled, monitored, or both controlled and monitored by a control unit (not shown). In at least one exemplary embodiment, heating may be achieved by treating the tobacco material with steam or a mixture of steam and air. The volatile matter 20 is collected and directed to a container 18 containing a pre-vapor formulation 16. In at least one exemplary embodiment, the volatile matter 20 is combined with the pre-vapor formulation 16 in the container 18 immediately after collection.

[0033] FIG. 2 is a flow chart illustrating a method of making a pre-vapor formulation, according to at least one exemplary embodiment.

[0034] As shown in FIG. 2, in at least one exemplary embodiment, the method generally includes mixing 75 a tobacco material and at least one additive to form a mixture, heating 100 the mixture, recovering 200 a volatile matter, and combining 300 the volatile matter with a pre-vapor formulation.

[0035] In at least one exemplary embodiment, the heating step 100 includes heating the tobacco material to a temperature in the range of about 50° C. to about 250° C. (e.g., about 100° C. to about 200° C. or about 125° C. to about 175° C.) to form a heated tobacco material. The heating step 100 may be carried out for a period of time of about 1 second to about 1 hour (e.g., about 2 seconds to about 50 minutes, about 5 seconds to about 40 minutes, about 10 seconds to about 30 minutes, or about 20 seconds to about 20 minutes). It will be apparent to one of ordinary skill in the art that the duration of the heating step will depend on the size of the container, the mass of tobacco to be heated and whether it has been stirred, the nature and age of the tobacco, the temperature to which the tobacco is heated, and any pre-treatment steps for the same tobacco.

[0036] In at least one exemplary embodiment, the heating step 100 is carried out at atmospheric pressure. In other exemplary embodiments, higher or lower pressures may be used.

[0037] In at least one exemplary embodiment, the tobacco material may include any number of materials belonging to the Nicotiana genus, hi at least one exemplary embodiment, the tobacco material includes a blend of two or more different tobacco varieties.

[0038] Examples of suitable types of tobacco material that may be used include, but are not limited to, flue-cured tobacco, burley tobacco, dark tobacco, Maryland tobacco, Orient tobacco, rare tobacco, specialty tobacco, mixtures thereof, and the like. The tobacco material may be provided in any suitable form, including, but not limited to, tobacco lamina, processed tobacco material (such as volume expanded or puffed tobacco), processed tobacco stems (such as cut rolled or cut puffed stems), reconstituted tobacco material, mixtures thereof, and the like.

[0039] In at least one exemplary embodiment, the tobacco material is in the form of a substantially dry tobacco mass.

[0040] In at least one exemplary embodiment, the tobacco material may be rotated, stirred, agitated, and combinations thereof during the heating process 100 .

[0041] In at least one exemplary embodiment, the tobacco material may be moistened or treated with additives prior to the heating step 100 and may be in the form of a slurry or moist tobacco mass. The additives may include at least one of a solvent, a flavorant, a pH modifier, and a casing solution. Additives may be added to the tobacco material to release salt-bound flavorants, to effect hydrolysis of flavorant precursors, or both. Additives may be selected to promote specific reactions, such as the Maillard reaction. Altering the pH of the tobacco may promote hydrolysis of glycosidically bound flavorants.

[0042] In at least one exemplary embodiment, the solvent comprises at least one of water, ethanol, glycerin, and propylene glycol. As described below, the solvent can enhance the extraction of tobacco-related flavor compounds and improve the efficiency of their transfer from the heat-treated tobacco material to the collection medium used in the collection step 200. The use of solvents of different polarity and / or volatility can result in tobacco flavorants with different sensory profiles. In at least one exemplary embodiment, a portion of the pre-vapor formulation can be used as the solvent.

[0043] Tobacco extracts obtained by non-selective solvent extraction may include extracted materials with different chemical properties and / or different molecular sizes and / or different molecular weights. The use of this type of extract in a pre-vapor formulation may pose problems due to compounds that may accumulate in the heating section of the e-vaporizing device, which may lead to buildup and chemical reactions with by-products. At least one exemplary embodiment method disclosed herein may include the use of highly volatile and mobile compounds that are eluted from tobacco by high vapor pressure.

[0044] In at least one exemplary embodiment, the flavoring may include any suitable flavoring, including menthol, mint flavors, fruit flavors, herbal flavors, vegetable flavors, and the like.

[0045] In at least one exemplary embodiment, the pH modifier comprises one of an acid or a base. The pH modifier is selected to adjust the pH of the tobacco material to a desired level. The pH of the tobacco material can range from about 1 to about 14, or from about 3 to about 12.

[0046] In at least one exemplary embodiment, the casing solution may include water, a humectant (such as propylene glycol), sugar, cocoa, licorice, fruit extracts, other ingredients, and combinations thereof.

[0047] In at least one exemplary embodiment, when the tobacco material is heated, volatiles are released and can be collected 200 .

[0048] In at least one exemplary embodiment, the method also includes recovering 200 volatile matter from the heated tobacco material and combining 300 the volatile matter with the pre-vapor formulation immediately following the recovering step 200. Thus, the volatile matter is combined with the pre-vapor formulation at the recovery location to minimize, reduce, or minimize and reduce at least one of losses and undesirable chemical reactions.

[0049] In at least one exemplary embodiment, the pre-vapor formulation can be maintained at or below room temperature prior to the combining step 300.

[0050] In at least one exemplary embodiment, the prevapor formulation includes a vapor former. Suitable vapor formers include, but are not limited to, polyhydric alcohols (such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerin), esters of polyhydric alcohols (such as glycerol mono-, di-, or triacetate), and aliphatic esters of mono-, di-, or polycarboxylic acids (such as dimethyl dodecanedioate and dimethyl tetradecanedioate). Examples of vapor formers are polyhydric alcohols or mixtures thereof, such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerin.

[0051] In at least one embodiment, the pre-vapor formulation can include propylene glycol and glycerin in a ratio of about 3:2. In at least one embodiment, the ratio of propylene glycol and glycerin can be substantially 2:3 and 3:7. In at least one embodiment, the vapor former is included in an amount ranging from about 40 weight percent based on the weight of the pre-vapor formulation to about 90 weight percent based on the weight of the pre-vapor formulation (e.g., about 50 percent to about 80 percent, about 55 percent to about 75 percent, or about 60 percent to about 70 percent).

[0052] In at least one exemplary embodiment, the pre-vapor formulation includes water, which may be present in an amount ranging from about 5 weight percent based on the weight of the pre-vapor formulation to about 40 weight percent based on the weight of the pre-vapor formulation, or from about 10 weight percent based on the weight of the pre-vapor formulation to about 15 weight percent based on the weight of the pre-vapor formulation.

[0053] In at least one exemplary embodiment, the vapor-forming substrate may include a single vapor former, such as glycerin. Alternatively, in some exemplary embodiments, the vapor-forming substrate may include a combination of two or more vapor formers.

[0054] In at least one embodiment, the pre-vaporized formulation may also include a flavoring agent in an amount ranging from about 0.01 percent to about 15 percent by weight (e.g., from about 1 percent to about 12 percent, or from about 2 percent to about 10 percent, or from about 5 percent to about 8 percent). The flavoring agent may be a natural flavoring agent or an artificial flavoring agent. In at least one embodiment, the flavoring agent is one of tobacco flavor, menthol, wintergreen, peppermint, herbal flavor, fruit flavor, nut flavor, liquor flavor, and combinations thereof. The flavoring agent may include one or more volatiles extracted from tobacco materials as disclosed herein.

[0055] In an embodiment, nicotine is included in the pre-vaporized formulation in an amount ranging from about 2 weight percent to about 6 weight percent (e.g., about 2 weight percent to about 3 weight percent, about 2 weight percent to about 4 weight percent, about 2 weight percent to about 5 weight percent) based on the total weight of the pre-vaporized formulation. In at least one embodiment, nicotine is added in an amount of up to about 5 weight percent based on the total weight of the pre-vaporized formulation. In at least one embodiment, the nicotine content of the pre-vaporized formulation is about 2 weight percent or more based on the total weight of the pre-vaporized formulation. In another embodiment, the nicotine content of the pre-vaporized formulation is about 2.5 weight percent or more based on the total weight of the pre-vaporized formulation. In another embodiment, the nicotine content of the pre-vaporized formulation is about 3 weight percent or more based on the total weight of the pre-vaporized formulation. In another embodiment, the nicotine content of the pre-vaporized formulation is about 4 weight percent or more based on the total weight of the pre-vaporized formulation. In another embodiment, the nicotine content of the pre-vaporized formulation is about 4.5 weight percent or more based on the total weight of the pre-vaporized formulation.

[0056] In at least one exemplary embodiment, the volatile matter may be present in the pre-vaporized formulation in an amount ranging from about 0.01 weight percent based on the weight of the pre-vaporized formulation to about 5 weight percent based on the weight of the pre-vaporized formulation (e.g., from about 0.5 weight percent to about 4 weight percent based on the weight of the pre-vaporized formulation, or from about 1 weight percent to about 3 weight percent based on the weight of the pre-vaporized formulation). Thus, the heating step 100 may be maintained, repeated, or maintained and repeated until the desired amount of volatile matter has been added to the pre-vapor formulation.

[0057] FIG. 3 is a flow chart illustrating the heating step of the method of FIG. 2 in accordance with at least one example embodiment.

[0058] As shown in FIG. 3, in at least one exemplary embodiment, the heating step 100 can include a pre-heating step 101. During this step, the tobacco material is heated to a first temperature for the first time. The heating step 100 can also include a first heating step 102 and a second heating step 102. The first heating step 102 can heat the tobacco material to a second temperature in a second heat, and the second heating step 103 can heat the tobacco material to a third temperature in a third heat. The pre-heating step 101, the first heating step 102, and the second heating step 103 can be at different times and at different temperatures. Thus, various volatiles (such as pyrazines, organic acids, and aromatic compounds) that can be released at different times, at different temperatures, or both at different times and at different temperatures can be recovered from the tobacco material and added to the pre-vapor formulation.

[0059] Although not shown, fewer or additional heating steps may be included in heating step 100.

[0060] FIG. 4 is a flow chart illustrating the recovering and combining steps of the method of FIG. 2 in accordance with at least one example embodiment.

[0061] 4, in at least one exemplary embodiment, the recovering step 200 can include inserting 202 an absorbent material into the heated tobacco material during the heating step 100, prior to the heating step 100, immediately after the heating step 100, and combinations thereof. Once the absorbent material is inserted into the tobacco material, the absorbent material adsorbs, absorbs, or adsorbs and absorbs 204 volatiles produced as the tobacco is heated.

[0062] In at least one exemplary embodiment, the absorbent material may be disposed within a flavorant cartridge coupled to an electronic vaping device such that flavor delivery may be achieved by elution of flavorant from an adsorbent into vapor vapor passing through the cartridge, and such that flavor delivery may be enhanced by heating the flavorant cartridge.

[0063] As used herein, an "sorbent" is a material that can condense or hold molecules of other substances on its surface, entrap other substances (i.e., by permeating other substances into its inner structure, into its pores, or both), or both. An absorbent can be any adsorbent, any absorbent, any material capable of performing these functions, and combinations thereof.

[0064] In at least one exemplary embodiment, the absorbent material may be at least one of an activated carbon absorbent material or other microporous material. The absorbent material may be any material capable of absorbing, adsorbing, or absorbing and adsorbing gas components onto its surface, or assimilating such components within its body. The absorbent material may include one or more adsorbents. Suitable absorbents, adsorbents, or absorbents and adsorbents may include, for example, carbon, such as activated carbon, alumina, silicates, molecular sieves, zeolites, and polydimethylsiloxane (PDMS). The absorbent material may be in the form of a plurality of beads or a single monolithic plate.

[0065] In at least one exemplary embodiment, the absorbent material can be selected to absorb, adsorb, or absorb and adsorb volatiles having a desired particle size to achieve selective absorption, adsorption, or absorption and adsorption of volatiles desired to be included in the pre-vapor formulation.

[0066] In at least one exemplary embodiment, the absorbent is a microporous material (i.e., a microporous absorbent), such as activated carbon. A microporous absorbent can have pores with widths, diameters, or widths and diameters of less than about 20 angstroms (Å).

[0067] In at least one exemplary embodiment, the method can also include desorbing 206 the volatiles from the absorbent material. The volatiles can be desorbed from the absorbent material by extraction in an aerosol-forming solvent, such as at least a portion of the pre-vapor formulation, during the combining step 300, as shown in Figure 4. Thus, the absorbent material can be placed in a container with at least a portion of the pre-vapor formulation or at least one component of the pre-vapor formulation (e.g., water or propylene glycol) to extract the volatiles from the absorbent material and form a mixture of the pre-vapor formulation and the extracted volatiles. The mixture can then be added to an additional amount of the pre-vapor formulation to form a pre-vapor formulation including the extracted volatiles.

[0068] In at least one exemplary embodiment, the volatiles may be desorbed from the absorbent using a solvent and then immediately combined with the pre-vapor formulation after collection of the volatiles.

[0069] In at least one exemplary embodiment, instead of combining the volatiles with the pre-vapor formulation, an absorbent material may be disposed within the electronic vaping device between the heater and the mouth end of the electronic vaping device such that the volatile flavorants may dissolve into the vapor during vaping.

[0070] In another exemplary embodiment, the desorption may include thermal desorption followed by bubbling the volatiles through a solvent trap, filter, or solvent trap and filter. The solvent may include a portion of the pre-vapor formulation or any other suitable solvent, such as water or ethanol.

[0071] FIG. 5 is a flow chart illustrating the recovering and combining steps according to at least one example embodiment.

[0072] As shown in FIG. 5, in at least one exemplary embodiment, instead of the collecting step 200 shown in FIG. 4, the collecting step 200 may include condensing 210 the volatile flavorant. The volatile flavorant may be condensed by cooling the volatiles as they are extracted from the tobacco material during the heating step 100. For example, the volatiles may travel through a tube from a container holding the tobacco material to a container holding the pre-vapor formulation, and the tube may be cooled to promote condensation along the length of the tube. As the volatiles cool, they may condense on the walls, surfaces, or walls and surfaces of the tube, where the condensate may be collected. In another exemplary embodiment, after the volatiles condense on the walls, surfaces, or walls and surfaces of the tube, the condensate may be drained into a collection vessel, such that the condensed volatiles may be combined with the pre-vapor formulation. The cooling may reduce the temperature of the volatiles to a temperature in the range of about -78°C to about 10°C.

[0073] In at least one exemplary embodiment, once the volatiles are condensed, the combining step 300 can include mixing 320 the condensed volatiles with the pre-vapor formulation.

[0074] As shown in FIG. 6, in at least one exemplary embodiment, instead of the recovering step 200 shown in FIGS. 4 and 5, the recovering step 200 may include bubbling 220 the volatiles through a solvent trap.

[0075] Moreover, when the words "generally" and "substantially" are used in connection with a geometric shape, exactness of the geometric shape is not required, and a tolerance of shape is intended to be within the scope of this disclosure. The terms "generally" and "substantially" used in conjunction with geometric terms are intended to include not only features that conform to the exact definition, but also features that come quite close to the exact definition.

[0076] When the term "about" is used herein in conjunction with a numerical value, the associated numerical value is intended to include a tolerance of ±10% around the stated numerical value. Additionally, when percentages are referred to herein, it is intended that such percentages are based on weight, i.e., weight percentages.

[0077] It will now be apparent that new, improved, and non-obvious methods of making pre-vapor formulations and electronic vaping devices have been described herein with sufficient detail to enable one of ordinary skill in the art to understand. Moreover, it will be apparent to those skilled in the art that numerous modifications, variations, substitutions, and equivalents exist for the features of the methods and electronic vaping devices that do not significantly depart from the scope of the present invention. Accordingly, it is expressly intended that all such modifications, variations, substitutions, and equivalents that fall within the scope of the present invention as defined by the appended claims be covered by the appended claims.

[0078] 1. A method of making a pre-vapor formulation, the method comprising: heating the tobacco material to a temperature in the range of about 50°C to about 250°C to form a heated tobacco material; recovering volatiles from the heated tobacco material; and immediately following said recovering step, combining said volatile fraction with a pre-vapor formulation. 2. The method of claim 1, further comprising the step of combining an additive with said tobacco material prior to said heating step. 3. The method of claim 2, wherein the additives include one or more of a casing solution, a solvent, a pH adjuster, and a flavoring agent. 4. The method of claim 3, wherein the solvent comprises one or more of water, ethanol, glycerin, and propylene glycol. 5. The method of claim 2, 3 or 4, wherein the additive is selected to promote the Maillard reaction. 6. The method of any of 2 to 5, wherein the additive is selected to promote enzymatic hydrolysis to facilitate release of flavoring agents. 7. The recovering step comprises: 7. The method of any one of 1 to 6, comprising inserting an adsorbent material within the heated tobacco material, the adsorbent material being configured to adsorb the volatiles. 8. The step of combining comprises: 8. The method of claim 7, further comprising desorbing said volatiles from said adsorbent material. 9. The step of combining comprises: 9. The method of claim 7 or 8, comprising disposing the adsorbent material in a reservoir containing the pre-vapor formulation. 10. Recovering the volatile matter comprises: 10. The method according to any one of 1 to 9, further comprising condensing the volatile matter. 11. Recovering the volatile matter comprises: 11. The method of any of 1 to 10, comprising bubbling the volatiles through a solvent trap. 12. The method of any one of 1 to 11, further comprising rotating the tobacco material during the heating step. 13. The method of any one of 1 to 12, wherein the tobacco material is in the form of one of a slurry, a moist tobacco mass, and a substantially dry tobacco mass. 14. The method according to any one of 1 to 13, further comprising maintaining the pre-vapor formulation at or below room temperature. 15. The method according to any one of 1 to 14, wherein the tobacco material is heated for about 2 seconds to about 1 hour. 16. The method of any one of 1 to 15, wherein the tobacco material comprises a blend of two or more different tobacco varieties. 17. The method of any one of 1 to 16, further comprising adjusting the pH of the tobacco material prior to the heating step.

Claims

1. 1. A method of making a pre-vapor formulation, the method comprising: heating the tobacco material to a temperature in the range of about 50°C to about 250°C to form a heated tobacco material; recovering volatiles from the heated tobacco material, the recovering step comprising: frothing the volatiles through a solvent trap; Immediately after the recovering step, mixing the volatile matter with a pre-vapor formulation; Including, The pre-vapor formulation includes a vapor former, and the vapor former is included in an amount of from about 40 weight percent based on the weight of the pre-vapor formulation to about 90 weight percent based on the weight of the pre-vapor formulation. method.

2. combining an additive with the tobacco material prior to the heating step. The method of claim 1 further comprising:

3. The method of claim 1 , wherein the additives further comprise one or more of a casing solution, a solvent, a pH adjuster, and a flavoring agent.

4. 4. The method of claim 3, wherein the solvent comprises one or more of water, ethanol, glycerin, and propylene glycol.

5. 5. The method of claim 2, 3 or 4, wherein the additive is selected to promote the Maillard reaction.

6. 6. A method according to any one of claims 2 to 5, wherein the additive is selected to promote enzymatic hydrolysis to aid in the release of flavouring agents.

7. 7. The method of any one of 1 to 6, wherein the step of recovering the volatiles comprises the step of condensing the volatiles.

8. The method of any one of claims 1 to 7, further comprising rotating the tobacco material during the heating step.

9. The method of any one of claims 1 to 8, wherein the tobacco material is in the form of one of a slurry, a moist tobacco mass, and a substantially dry tobacco mass.

10. The method of any one of claims 1 to 9, further comprising maintaining the pre-vapor formulation at or below room temperature.

11. The method of any one of claims 1 to 10, wherein the tobacco material is heated for about 2 seconds to about 1 hour.

12. The method of any one of claims 1 to 11, wherein the tobacco material comprises a blend of two or more different tobacco varieties.

13. adjusting the pH of the tobacco material before the heating step; 13. The method of any one of 1 to 12, further comprising:

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