Components Containing Aerosol-Forming Materials and Uses Thereof

Abstract

The present invention relates to a composition comprising an aerosol-generating material comprising a dry precursor material comprising an extract from a perfume-containing and / or active-containing plant material, and optionally an aerosol-forming material. The composition may be used to generate an aerosol. For example, the composition may be used in a combustion or non-combustion aerosol delivery system. The present invention also relates to an aerosol delivery system comprising the composition, and a method of providing the composition.

Description

[Technical field]

[0001] The present invention relates to a component comprising an aerosol-forming material, a method for making the component and uses thereof. [Background technology]

[0002] Aerosol-generating materials for use in combustion or non-combustion aerosol delivery systems may contain a variety of different actives and / or flavorants. Factors such as the concentration of volatile active and / or flavoring ingredients in the aerosol-generating material and the stability of the aerosol-generating material affect the characteristics of the aerosol generated. Summary of the Invention

[0003] According to a first aspect of the present invention, there is provided a component comprising an aerosol-forming material comprising a dry precursor material comprising an extract from perfume-containing and / or active-containing plant material.

[0004] In some embodiments, the components are about 50 m 2 / g or less BET surface area.

[0005] In some embodiments, the component is a compressed tablet.

[0006] In some embodiments, the component comprises a binder.

[0007] In some embodiments, the binder is present in an amount of about 0.1% to about 30% by weight, based on the total weight of the tablet.

[0008] In some embodiments, the binder is selected from the group consisting of starches, polysaccharides, pectins, cellulose, cellulose derivatives such as carboxymethylcellulose, and alginates.

[0009] In some embodiments, the components have a size of about 1 mm to about 20 mm.

[0010] In some embodiments, the component consists essentially of dry aerosol-forming material and optional binder.

[0011] In some embodiments, the aerosol generating material further comprises an aerosol forming material.

[0012] In some embodiments, the precursor material comprises from about 10 to about 95% by weight extract derived from flavor- or active-containing plant material.

[0013] In some embodiments, the precursor material comprises from about 1 to about 36% by weight of the aerosol-forming material.

[0014] In some embodiments, the precursor material comprises from 0 to about 40% by weight of excipients.

[0015] In some embodiments, the aerosol-forming material comprises from about 45% to about 99% by weight of a dry extract derived from flavor- or active-containing plant material.

[0016] In some embodiments, the aerosol-forming material comprises from about 1 to about 34% by weight of the aerosol-forming material.

[0017] In some embodiments, the aerosol-forming material comprises from 0 to about 25% by weight of an excipient.

[0018] In some embodiments, the plant material is selected from the group consisting of tobacco, eucalyptus, star anise, cocoa, and hemp.

[0019] In some embodiments, the extract from the flavor-containing or active-containing plant material is an aqueous extract.

[0020] In some embodiments, the extract from flavor-containing or active-containing plant material is an aqueous tobacco extract.

[0021] In some embodiments, the dry aerosol-forming material contains from about 40 to about 99% by weight tobacco solids.

[0022] In some embodiments, the aerosol-forming material has a moisture content of about 5% or less (calculated on a wet weight basis).

[0023] In some embodiments, the components include a heating material embedded within the aggregates. In some embodiments, the heating material is heated by electrical resistance. In some embodiments, the heating material is a susceptor.

[0024] In some embodiments, the component is for use in an aerosol delivery system.

[0025] According to a second aspect of the present invention there is provided an article comprising one or more components according to the first aspect.

[0026] In some embodiments, the article includes a means for preventing or reducing absorption of moisture by the dry aerosol-forming material.

[0027] In some embodiments, the means is provided separately from the aggregate or aggregates.

[0028] In some embodiments, the device comprises a film or wrapper that includes a moisture impermeable coating or an adsorbent or desiccant material.

[0029] According to a third aspect of the invention there is provided a non-combustion aerosol delivery system comprising a component according to the first aspect or an article according to the second aspect.

[0030] In some embodiments, the system is configured to heat the components to form a vapor and / or an aerosol.

[0031] In some embodiments, the system includes an additional aerosol-generating material that is heated to form an aerosol and / or vapor, and optionally, the additional aerosol-generating material is a liquid.

[0032] In some embodiments, the component is heated by aerosol and / or vapor generated from an additional aerosol-forming material.

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

[0034] According to a fourth aspect of the present invention there is provided a method of providing a component comprising the steps of drying a precursor material comprising an extract from perfume-containing and / or active-containing plant material to form an aerosol-forming material, and forming the aerosol-forming material into the component by compression.

[0035] In some embodiments, the precursor material is dried by spray drying or freeze drying.

[0036] In some embodiments, the method includes adding a binder to particles of the aerosol-forming material before or during formation of the aerosol-forming material into components.

[0037] In some embodiments, the method includes adding an aerosol-forming material to particles of the aerosol-forming material before or during formation of the aerosol-forming material into the component.

[0038] In some embodiments, the aerosol-generating material is compressed into components by extrusion.

[0039] According to a fifth aspect of the present invention there is provided a method of providing a component comprising an aerosol-generating material, the method comprising the steps of freezing a precursor material comprising an extract from fragrance-containing and / or active-containing plant material and drying the frozen precursor material to form the component comprising an aerosol-generating material.

[0040] 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]

[0041] [Figure 1] 1 is a side cross-sectional view of a first embodiment of a consumable including components described herein. [Diagram 2] FIG. 2 is a perspective view of a non-combustion aerosol delivery device for generating aerosol from the consumable components shown in FIG. 1. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0042] An aerosol-forming material is a material that is capable of generating an aerosol when, for example, heated, irradiated, or in any other way energized.

[0043] Conventional aerosol generating materials, including tobacco materials or tobacco extracts, can be used in combustion and non-combustion aerosol generating devices, including hybrid devices and tobacco heating products, to provide users with an aerosol with authentic tobacco taste and texture. One problem encountered with such materials is that the content of flavors, other volatile compound(s) and nicotine decreases with storage of the aerosol generating material, especially toward the end of the material's life. This is because the more volatile components, including nicotine and many flavors and aromas, are easily released from the material. Furthermore, when the moisture content of the aerosol generating material increases due to moisture absorption, the release of substances such as nicotine and flavors is adversely affected. Aerosol generating materials produced using conventional methods and procedures generally need to be used within 1-3 days of production. Thus, there is a need to improve the shelf life of aerosol generating materials.

[0044] A further problem associated with conventional aerosol-forming materials that include tobacco materials or tobacco extracts is that the concentrations of desired components, such as nicotine and flavors, are relatively low. This limits the concentration of these desired components in the generated aerosol. Furthermore, this means that a relatively large amount of the aerosol-forming material is required, and therefore a large amount of energy is required to heat the aerosol-forming material to release the desired components.

[0045] The present invention relates to compositions comprising a dried precursor material comprising an extract from a fragrance-containing and / or active-containing plant material and, optionally, an aerosol-forming material. In some embodiments, the extract is a liquid solution or suspension and may be dried or dehydrated using a process such as spray drying or freeze drying. The dried or dehydrated aerosol-forming material may be formed from a precursor material comprising an extract from a fragrance-containing and / or active-containing plant material and, optionally, an aerosol-forming material.

[0046] Aerosol-forming materials that include dried extracts from fragrance-containing and / or active-containing plant materials contain high concentrations of fragrances and / or actives, with little or no material contributing to the aerosol generated from the dry aerosol-forming material. Thus, small amounts of aerosol-forming material are sufficient to generate an aerosol with the desired active and fragrance content. Furthermore, the aerosol may be generated with a relatively low level of energy input.

[0047] An additional advantage of the aerosol-forming materials used as solid substrates is that the low water content reduces the problems associated with "hot puffs" as known in the art.

[0048] In some embodiments, the dry aerosol forming material has a moisture content of 0 to about 10%, or 0 to about 5%, (calculated on a wet weight basis) as measured by gas chromatography-thermal conductivity detector (GC-TCD) or Karl Fischer titration. In some embodiments, the moisture content of the dry aerosol forming material is less than about 3% by weight, e.g., about 0 to about 3% by weight, or about 0.5 to about 2.5% by weight.

[0049] Karl Fischer titration is a classical method of chemical analysis to reliably determine the amount, even trace amounts, of water in a sample. The method can be easily performed using an automated Karl Fischer titrator. Similarly, the use of GC-TCD is also an established method to reliably determine the water content in a sample.

[0050] Unless otherwise stated, references to water content herein are references to water content as measured by Karl Fischer titration.

[0051] Dry aerosol-forming materials can be hygroscopic, so steps must be taken to ensure that the aerosol-forming material does not absorb moisture during processing, during incorporation into the final product, and during storage in that final product prior to use.

[0052] Typically, it is not necessary to protect conventional aerosol-generating materials from moisture in the surrounding environment. This is because conventional aerosol-generating materials are not hygroscopic and are not particularly sensitive to moisture. Furthermore, humectants such as glycerol are often included in conventional aerosol-generating materials in appropriate amounts to target a specific moisture level in the aerosol-generating material. The highly concentrated nature of the dry aerosol-generating materials used in the present invention means that even small amounts of moisture absorption can be very detrimental to the properties of the aerosol-generating material and the quality of the aerosol produced. Furthermore, water absorption can occur to such an extent that the dry powder takes on a paste-like consistency, which is undesirable in the compositions and consumables described herein.

[0053] Preventing or reducing the absorption of water by the aerosol-forming material also helps manage or avoid the phenomenon known as "hot puffs."

[0054] The present disclosure provides a component comprising an aerosol-generating material. The component may, in some embodiments, comprise multiple particles of the aerosol-generating material that have aggregated to form the component. In other embodiments, rather than being formed by combining multiple particles, the component may be a single piece or chunk of the aerosol-generating material.

[0055] The inventors have discovered that by controlling the surface area, density and / or porosity of the components comprising the aerosol-generating materials disclosed herein, control is provided over the release of the aerosol generated by heating the components, meaning that a predictable, consistent and sustained release of a desired aerosol component can be provided, with significant benefits for the user.

[0056] Components according to the present disclosure have a relatively high density; for example, in some embodiments, the density of the components may be equal to or greater than the density of the aerosol-generating material used to form them.

[0057] In some embodiments, the components may be formed by processes such as molding, extrusion or compression of the aerosol-generating materials. These processes may result in the formation of agglomerates of particles.

[0058] In other embodiments, liquid precursor materials are frozen to form units such as beads, e.g., by exposure to liquid nitrogen, and then dried, e.g., by lyophilization, to form components. This process offers greater control over the morphology of the dried product, and control of the size and shape of the pre-frozen beads allows for the production of lyophilized beads with selected surface areas and potentially different aerosol release characteristics.

[0059] The relatively high density of the components of the present disclosure also allows for good handling.

[0060] Additionally, the relatively small surface area to volume ratio of the components reduces the amount of moisture that can be absorbed by the aerosol-forming material because the aerosol-forming material inside the components is exposed to less moisture.

[0061] A further advantage associated with the components of the present invention is that the size and shape of the components may be selected to control or enhance aerosol generation and release. In some embodiments, the size and shape of the components may be selected to maximize surface area, for example, to facilitate air flow over or through the component during heating, to enhance heat transfer, and / or to control aerosol generation and release.

[0062] In some embodiments, components are provided having a size or shape selected to provide a desired aerosol release profile upon heating. Larger components and / or components having a smaller surface area to volume ratio tend to release aerosol more slowly and over a longer period of time than smaller components and / or components having a larger surface area to volume ratio.

[0063] Components In some embodiments, the components disclosed herein include agglomerates of particles of dry aerosol-forming material. Such agglomerates are collections of bound particles.

[0064] In some embodiments, the agglomerates are dense agglomerates, where the aggregation and bonding of the particles of the aerosol-generating material results in little or no voids between the particles that make up the agglomerates. As such, the agglomerates are relatively dense and not very porous. The surface area to volume ratio is relatively small, and may be significantly smaller than the surface area to volume ratio of the particles that make up the agglomerates prior to aggregation.

[0065] In some embodiments, the dry aerosol-generating material is formed into components having desired properties. Various processes, such as molding, extrusion, or compression, can be used to form the components from particles of the aerosol-generating material. In some embodiments, these processes apply some compressive force to the aerosol-generating material to form the components. This densifies the components and provides them with sufficient structural integrity to withstand processing, transportation, and storage. The compressive force also allows the components to be formed in the desired size and shape.

[0066] In some embodiments, the population of particles may be subjected to a compressive force to help bind the particles together and increase the stability of the aggregated components. For example, a mixture including particles of the aerosol-generating material and any other materials may be compressed in a conventional pill press, tablet press, or the like, where the materials may be compressed by the application of force. This force may be, for example, on the order of 2 to 20 kN.

[0067] Components formed by such coalescence processes, optionally involving the application of a compressive force, can have a density greater than the density of the materials used to form them.

[0068] Low porosity / high density components have the advantage of being heated slowly and providing stable, sustained aerosol generation. Such components also reduce in volume and their compact form can be used to reduce the size of consumables.

[0069] The components formed by agglomerating the particles can take the form of, for example, tablets or beads. In some embodiments, the components have a particle size of about 1 mm to about 10 mm. For non-spherical shapes, the size of the components can be the largest dimension of the components. In some embodiments, the components have an average size of at least about 1 mm, at least about 1.5 mm, at least about 2 mm, at least about 2.5 mm, or at least about 3 mm. Additionally or alternatively, the components can have an average size of about 10 mm or less, about 9 mm or less, about 8 mm or less, about 7 mm or less, about 6 mm or less, about 5 mm or less, about 4.5 mm or less, or about 4 mm or less.

[0070] Considering the effect of component porosity, density and size on aerosol generation, the use of components described herein can make it possible to control the release of the aerosol. The density and porosity of one or more components may be selected to provide desired aerosol release characteristics.

[0071] In some embodiments, the component consists of or consists essentially of an aerosol-generating material formed by drying the precursor material described herein. In other embodiments, the component may further comprise other additional materials. For example, the agglomerate may further comprise particles of a different aerosol-generating material, such as particles of tobacco material or particles of gel or dry gel. In other embodiments, the particles of the aerosol-generating material may be aggregated with particles of other materials to give the agglomerate desired properties, such as density, porosity, absorption or adsorption. For example, the agglomerate may comprise particles of one or more structural materials, such as chalk. In addition to structural benefits, this material may also absorb moisture and thus reduce the amount of moisture absorbed by the dried extract. In some embodiments, the agglomerate comprises particles that contain and / or retain flavorings.

[0072] In some embodiments, the components may further include one or more functional materials.

[0073] When different materials make up a component, these materials may be homogeneously mixed or heterogeneously mixed, hi other embodiments, a component may include separate layers or portions of different materials.

[0074] In some embodiments, the dry aerosol-generating material is sticky, and this stickiness may be sufficient to hold the formed material of the components together, hi some embodiments, the stickiness of the aerosol-generating material may increase with the moisture content of the material, so that the moisture content of the aerosol-generating material may be increased to provide an appropriate level of stickiness to form components of suitable stability.

[0075] In some embodiments, the viscosity of the aerosol-generating material can be increased by adding an aerosol-forming material such as glycerol or propylene glycol. To achieve this effect, it may be necessary to add the aerosol-forming material in an amount of at least 15% by weight, based on the total weight of the components.

[0076] In some embodiments, the components do not include binders to aid in formation and increase the strength of the components, in such embodiments, the compressive forces applied to the material to form the components can provide sufficient strength and stability to the components.

[0077] In some embodiments, the components include one or more binders for binding or adhering materials within the components together, for example, the one or more binders are selected from the group consisting of starch, polysaccharides, pectin, cellulose, cellulose derivatives such as carboxymethylcellulose, and alginates.

[0078] In some embodiments, the amount of binder used to adhere the particles that make up the components to one another is about 1 to about 30% by weight based on the weight of the total components, hi some embodiments, the amount of binder used is up to about 20%, up to about 15%, up to about 10%, or up to about 5% by weight of the total components.

[0079] In some embodiments, it is desirable to include as little binder as possible. For example, the components may include 0.1 to 10% binder by weight. In some embodiments, the components include no more than about 7%, 6%, 5%, 4%, 3%, or 2% binder by weight. In some embodiments, the components include one or more binders in a total amount of about 2 to about 5% by weight.

[0080] When forming the components described herein, the aerosol-generating materials and any additional components are mixed with any binder or aerosol-forming material included. The binder or aerosol-forming material may be added to the other materials before or during mixing. In some embodiments, a high shear mixer is used to mix the materials and form the components. The high shear mixer can be used to hydrate the binder and enhance its binding effect.

[0081] The mixture can then be formed into a component. In some embodiments, this includes compressing the mixture to help bind the materials together and increase the stability of the component. Suitable component formation processes include molding, compression and extrusion. The density and porosity of the resulting component can be tailored by selecting the appropriate forces applied by these processes.

[0082] Compression or compaction In some embodiments, the component is formed by compression or compaction. In such embodiments, the component can be a tablet or pill. First, the composition is filled into a die. The amount of composition is determined by the volume of the die. Then, a punch is lowered into the die and the powder is uniaxially compressed. The porosity of the resulting component can be controlled by adjusting the compression force applied by the punch. In some embodiments, the component has a porosity of about 5 to about 20%.

[0083] When compression of a composition results in a strengthening of the composition, the result is consolidation, which increases the mechanical strength of the component as a result of the bonding of materials within the strengthened composition.

[0084] When low pressure is applied to the composition in a die, the process is called molding. In such embodiments, the use of a binder may be required to provide the necessary strength and structural integrity to the resulting component.

[0085] Extrusion In some embodiments, the components are formed by extrusion of a composition that includes an aerosol-generating material. Extrusion involves feeding the composition through an orifice to create an extruded mass. The process of applying pressure to the composition in combination with shear forces results in a solid formed structure. This structure or mass can then be cut into components of desired size with further processing options such as spheronization.

[0086] Extrusion can be carried out using one of the major types of extruders, such as screw, screen and basket, roll, and ram extruders. Forming components by extrusion has the advantage that this process combines mixing, conditioning, homogenization, and shaping of the composition.

[0087] In some embodiments, during extrusion, the free-flowing composition is subjected to elevated pressure and temperature and forced through an orifice, such as a shaping die, to form an extruded solid mass. In some embodiments, the extruded mass has an elongated form and / or may be cut into segments of a desired length as it exits the orifice. The rod-shaped extruded mass can then be cut into segments of a desired length.

[0088] In some embodiments, the composition including the aerosol-forming material is exposed in the extruder to a temperature of from about 40° C. to about 150° C., or from about 80° C. to about 130° C. The composition may be exposed to a pressure ranging from about 2 bar to about 100 bar, or from about 5 bar to about 60 bar, depending on the die design used.

[0089] In some embodiments, extrusion may be a generally dry process, and the extruded composition is a substantially dry material that includes dry aerosol-forming material and, optionally, other particulate materials including, for example, binders, diluents, solid flavor modifiers, and the like.

[0090] In some embodiments, a liquid aerosol-forming material, such as glycerol, propylene glycol, or others discussed herein, can be added to the composition to be extruded. Adding a liquid to the precursor composition in this manner not only imparts the liquid to the surface, but also impregnates the extruded material as a result of the vigorous mixing caused by the pressure and high shear forces of the extruder. If the liquid is an aerosol-forming agent, this can result in a high availability of the aerosol-forming agent in the generated component to promote aerosolization of the active and / or flavoring ingredients from the aerosol-generating material in the component.

[0091] In some embodiments, the one or more aerosol forming agents are included in an amount of about 3% to about 30% by weight of the extruded composition, preferably in an amount of about 15% to about 30% by weight.

[0092] The extruded mass is shaped by the orifice or die through which it is forced. In some embodiments, the extruded mass is cut into pieces of a desired length. The pieces thus formed may be components or may undergo further processing to form components.

[0093] In some embodiments, the orifice or die is shaped 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 different cross-sectional shapes, including ovals, polygons (e.g., triangles, squares, etc.), and stars.

[0094] In some embodiments, the extruded composition is formed into a desired shape selected to enhance or facilitate aerosol release upon heating, for example, by providing a form with a large surface area per unit volume. This large surface area may be provided on the exterior surface of the extruded component, for example, by selecting a cross-sectional shape having a large perimeter. Alternatively or additionally, the large surface area may be provided by creating channels within the extruded component.

[0095] In some embodiments, different materials can be extruded together to form a component having separate sections or layers of different materials, or the extrusion process can mix different materials to provide them in a blended form in the extruded product.

[0096] Dry aerosol-generating materials The aerosol-generating material comprises a dried extract from a flavor-containing and / or active-containing plant material. In some embodiments, the aerosol-generating material further comprises an aerosol-forming material.

[0097] In some embodiments, the aerosol-generating material is formed by drying a precursor material that includes an extract from a flavor-containing and / or active-containing plant material. The drying process is selected to preserve desired components of the precursor material, and thus the aerosol-generating material may include one or more actives and / or flavors.

[0098] In some embodiments, the precursor material further comprises one or more aerosol-forming materials. Additionally or alternatively, one or more aerosol-forming materials may be added to the dry precursor material to provide an aerosol-generating material having a desired aerosol-forming material content.

[0099] The precursor material and / or the dry aerosol forming material may also optionally include one or more other functional materials.

[0100] Thus, the aerosol-generating material may include one or more active agents and / or flavorings, and optionally one or more aerosol-forming materials. The precursor material and / or the dry aerosol-generating material may also optionally include one or more other functional materials.

[0101] The present invention takes advantage of aerosol generating materials that are formulated to have a long shelf life and therefore can be easily transported and stored. Without wishing to be bound by any particular theory, it is hypothesized that the low moisture content of the dry aerosol generating materials reduces the evaporation of other solvents over time and reduces the decomposition of nicotine and / or other volatile compounds. The low moisture content also inhibits microbial growth. Compositions including the dry aerosol generating materials described herein are stable over a range of temperatures and humidities, resulting in a long shelf life and therefore easy storage and transport. In some embodiments, the compositions may be stored at temperatures ranging from 0 to 35°C. In some embodiments, the compositions may be stored at a relative humidity of up to about 30%, or even up to about 50%, prior to use.

[0102] Aerosol-generating materials also have the advantage of having a high concentration of the desired components, meaning that a relatively small amount of the aerosol-generating material is needed and less energy is needed to heat and release the desired components. Importantly, the aerosols generated from these materials also provide a reasonable intensity of authentic tobacco flavor.

[0103] A further advantage of the aerosol-forming materials is that they can be used as solid aerosol-generating substrates in hybrid systems or tobacco heating products (THPs), making the invention versatile enough for use in a variety of products without the need for further processing.

[0104] In some embodiments, the extract from the perfume-containing or active-containing plant material is an extract obtained by contacting the plant material with a suitable solvent, such as an aqueous solvent or an alcohol, such as ethanol, and the liquid portion containing the solvent and any dissolved plant components is then separated or partially separated from the remaining solid plant material to provide the extract contained in the precursor composition, which can then be dried.

[0105] In some embodiments, the extract from flavorant- or active-containing plant material is an extract from tobacco material.

[0106] The tobacco extract or material may be from or may be any type of tobacco and any part of the tobacco plant, including tobacco blades, stems, stalks, ribs, crumbs and bits, or a mixture of two or more thereof. Suitable tobacco extracts or materials include the following types: Virginia or flue-cured tobacco, Burley tobacco, Oriental tobacco, or blends of tobacco materials, optionally including those listed herein. Tobacco, such as dry ice expanded tobacco (DIET), may be expanded 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, roasted, or otherwise pre-processed. The tobacco material may be provided in the form of cut rag tobacco. The cut rag tobacco may have a cut width of at least 15 cuts / inch (about 5.9 cuts / cm, which corresponds to a cut width of about 1.7 mm). Cut rag tobacco can be formed from a mixture of tobacco material forms, such as a mixture of one or more of reconstituted tobacco, leaf tobacco, extruded tobacco, and band-cast tobacco.

[0107] The precursor material that is dried to form the aerosol-forming material may comprise at least about 10%, at least about 15%, at least about 20%, at least about 25%, at least about 30%, at least about 35%, or at least about 40% by weight tobacco solids (calculated on a wet weight basis). Additionally or alternatively, the precursor material may comprise up to about 60%, up to about 55%, up to about 50%, up to about 45%, or up to about 40% by weight tobacco solids (calculated on a wet weight basis). In some embodiments, the precursor material comprises between about 20% and about 40% by weight tobacco solids (calculated on a wet weight basis).

[0108] In some embodiments, the precursor material comprises at least about 10% by weight, at least about 20% by weight, at least about 30% by weight, at least about 40% by weight, at least about 50% by weight, at least about 60% by weight, at least about 70% by weight, at least about 80% by weight, or at least about 90% by weight of an extract derived from tobacco or other flavor- or active-containing plant material (calculated on a wet weight basis). Alternatively or additionally, the precursor material may comprise up to about 99% by weight, up to about 90% by weight, up to about 80% by weight, up to about 70% by weight, or up to about 60% by weight of an extract derived from tobacco or other flavor- or active-containing plant material (calculated on a wet weight basis). In some embodiments, the precursor material comprises about 50% by weight of a tobacco extract (calculated on a wet weight basis).

[0109] In some embodiments, the aerosol-forming material may comprise at least about 45%, at least about 50%, at least about 60%, at least about 70%, at least about 80%, at least about 90%, or at least about 95% by weight of tobacco material or tobacco extract, or flavorant- or active-containing plant material extract (calculated on a dry weight basis). In some embodiments, the aerosol-forming material may comprise from about 60 to about 80% by weight of tobacco extract (calculated on a dry weight basis).

[0110] In some embodiments, the dry aerosol forming material may contain from about 2% to about 10% nicotine by weight, or from about 3% to about 6% nicotine by weight (calculated on a dry weight basis).

[0111] In some embodiments, the precursor material comprises about 50% v / v tobacco extract. When the precursor material comprises about 50% v / v tobacco extract, and the tobacco extract has a tobacco solids content of about 55 to about 60% v / v, the overall tobacco solids content of the precursor material is about 27.5 to about 30% v / v.

[0112] In some embodiments, the tobacco extract has a solids content of about 40% to about 65%, about 45% to about 65%, or about 40% to about 60% by weight (calculated on a wet weight basis). In some embodiments, the moisture content of the tobacco extract is about 35% to about 65%, or about 35% to about 55% by weight (calculated on a wet weight basis). In some embodiments, the nicotine content of the tobacco extract is about 1% to about 5% by weight (calculated on a wet weight basis).

[0113] In some embodiments, the dry aerosol-forming material may comprise at least about 45%, at least about 50%, at least about 60%, at least about 70%, at least about 80%, at least about 90%, or at least about 95% tobacco solids by weight (calculated on a dry weight basis). Additionally or alternatively, the aerosol-forming material may comprise up to about 99%, up to about 98%, up to about 95%, up to about 90%, or up to about 80% by weight tobacco solids by weight. In some embodiments, the dry aerosol-forming material may comprise from about 60 to about 80% tobacco solids by weight (calculated on a dry weight basis).

[0114] In some embodiments, the tobacco extract is an aqueous tobacco extract. In some embodiments, the tobacco extract may be concentrated and then diluted before being added to the precursor material and dried. In other embodiments, the tobacco extract may not be concentrated and may be used directly to the precursor material.

[0115] The precursor material may be in the form of a slurry, suspension, gel, liquid or solid, but in some potentially preferred embodiments is in the form of a suspension or liquid, hi some embodiments, particles of solid material may be removed from the extract and / or precursor material by filtration and / or centrifugation.

[0116] In some embodiments, it may be desirable for any particles in the precursor composition to have an average particle size of about 3 mm or less, 1 mm or less, about 0.5 mm or less, or to have an average particle size of about 0.3 mm or less, as measured by sieving or by observing the size of the particles by SEM.

[0117] The water content of the precursor material can be at least about 20% by weight, at least about 30% by weight, at least about 40% by weight, at least about 50% by weight, at least about 60% by weight, at least about 70% by weight, at least about 80% by weight, or at least about 90% by weight on a wet weight basis. Alternatively or additionally, the water content of the precursor material can be up to about 95% by weight, up to about 90% by weight, up to about 85% by weight, up to about 80% by weight, up to about 75% by weight, up to about 70% by weight, up to about 65% by weight, up to about 60% by weight, up to about 55% by weight, or up to about 50% by weight on a wet weight basis. In some embodiments, the water content of the precursor material is about 40% to about 50% by weight (50% to 60% v / v%) on a wet weight basis. When the water content of the precursor material is low, the spray / freeze drying process is quicker because there is less water to remove.

[0118] In some embodiments, the dry aerosol-generating material and / or the precursor material includes one or more active agents, which may be obtained from an extract or may be added. In some embodiments, an extract from a flavored or active-containing plant material includes the active agents.

[0119] The 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, dietary supplements, nootropics, and psychotropic drugs. The active substance may include, 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 another botanical substance.

[0120] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0121] In some embodiments, the precursor material may include extracts from other plant source(s) along with or in place of tobacco extract.

[0122] As described herein, an extract may comprise or be derived from one or more plants or components, derivatives or extracts thereof. As used herein, the term "botanical" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fiber, stems, roots, seeds, flowers, fruits, pollen, husks, shells, etc. Extracts may comprise or be derived from plants in the form of liquids, gases, solids, powders, dusts, crushed particles, granules, pellets, shreds, strips, sheets, etc. Exemplary botanicals include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, bay, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea, such as green or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, Lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiane, marjoram, olive, lemon balm, lemon basil, chives, Calvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. The mint may be selected from the following mint varieties: Mentha americana, Mentha cv, Egyptian mint, Mentha piperita, Eau de cologne mint, Candy mint, Curly mint, Kentucky kernel mint, Horse mint, Pineapple mint, Pennyroyal mint, Green mentha, and Apple mint.

[0123] In some embodiments, the extract comprises or is derived from one or more plants selected from eucalyptus, star anise, cocoa, and hemp, or components, derivatives, or extracts thereof.

[0124] In some embodiments, the extract comprises or is derived from one or more plants selected from rooibos and fennel, or components, derivatives or extracts thereof.

[0125] In some embodiments, the aerosol-generating and / or precursor material comprises one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiol acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabichromene (CBC), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), and cannabielsoin (CBE), cannabicitran (CBT).

[0126] The aerosol-generating material and / or precursor material may include one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD) and THC (tetrahydrocannabinol).

[0127] The aerosol-generating material and / or precursor material may include cannabidiol (CBD).

[0128] The aerosol generating and / or precursor materials may include nicotine and cannabidiol (CBD).

[0129] The aerosol-generating and / or precursor materials may include nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol).

[0130] In some embodiments, the aerosol-generating material further comprises an aerosol-forming material, hi some embodiments, the aerosol-forming material is included in the precursor material.

[0131] The aerosol-forming material may include one or more components capable of forming an aerosol. The aerosol-forming agent may be, for example, a polyol aerosol generating agent or a non-polyol aerosol generating agent. It may be a solid or liquid at room temperature, but is preferably a liquid at room temperature.

[0132] In some embodiments, the aerosol forming material may include one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0133] In some embodiments, the aerosol forming agent comprises one or more 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 / or aliphatic esters of mono-, di-, or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate. In some embodiments, the aerosol forming material comprises one or more compounds selected from erythritol, propylene glycol, glycerol, vegetable glycerin (VG), triacetin, sorbitol, and xylitol.

[0134] In some embodiments, the aerosol-forming material comprises, consists essentially of, or consists of glycerol. Glycerol provides a visible aerosol when the aerosol generating device is used. Aerosol generating devices that provide a visible aerosol are generally preferred by consumers because they allow them to visualize the product and what they are consuming. This makes glycerol a desirable choice for the aerosol-forming material. Propylene glycol has the advantage of being a better perfume carrier than glycerol.

[0135] Combinations of two or more aerosol forming agents may be used, in equal or differing proportions.

[0136] In some embodiments, the precursor material comprises at least about 1%, at least about 5%, at least about 10%, or at least about 20% by weight of aerosol-forming material (calculated on a wet weight basis). Additionally or alternatively, the precursor material may comprise up to about 40%, up to about 35%, up to about 30%, up to about 25%, up to about 20%, or up to about 10% by weight of aerosol-forming material (calculated on a wet weight basis).

[0137] In embodiments of the invention in which the aerosol-forming material is glycerol, the precursor material may contain up to 36% glycerol by weight. The inventors have demonstrated that dry weight content levels of aerosol-forming material of up to 36% by weight (calculated on a dry weight basis) are possible.

[0138] The amount of glycerol in the precursor material, and therefore in the dry aerosol material, is important because it is both an aerosol-forming material and a plasticizer. Too high a concentration of glycerol can be detrimental to the critical temperature of the product during the freeze-drying process, and can cause the product to collapse when the critical temperature of the formulation is exceeded. On the other hand, sufficient glycerol should be included to provide sufficient and pleasant aerosol to the consumer.

[0139] It is particularly surprising that precursor materials including glycerol and some other aerosol-forming materials can be freeze-dried because such materials are believed to have antifreeze properties. Nevertheless, the inventors have discovered that precursor materials including glycerol can be freeze-dried to form highly useful aerosol-generating materials.

[0140] In some embodiments, the dry aerosol-forming material may comprise at least about 1% by weight, at least about 5% by weight, at least about 10% by weight, at least about 20% by weight, at least about 30% by weight, or at least about 40% by weight of the aerosol-forming material (calculated on a dry weight basis).

[0141] In some embodiments, the dry aerosol-forming material may comprise from about 1 to about 34% by weight or from about 17 to about 34% by weight of the aerosol-forming material (calculated on a dry weight basis). In some embodiments where the aerosol-forming material is glycerol, the dry aerosol-forming material may comprise from about 13 to about 34% by weight of glycerol (calculated on a dry weight basis).

[0142] In embodiments in which burley tobacco is used, the aerosol-forming material may include about 17 to about 36% by weight glycerol. The amount of glycerol in the aerosol material is important as it is both an aerosol-forming material and a plasticizer. If the concentration of glycerol is too high, it may be detrimental to the critical temperature of the product during the freeze-drying process and may result in the collapse of the product if the critical temperature of the formulation is exceeded. On the other hand, sufficient glycerol should be included to provide a sufficient and pleasant aerosol to the consumer.

[0143] In some embodiments, the aerosol-generating material and / or the precursor material further comprises one or more excipients. In some embodiments, the excipients stabilize and preserve the precursor material, and the inventors have found that the inclusion of an excipient is particularly important for stability when the precursor material comprises glycerol as the aerosol-forming material. The excipients may also act as bulking or filler materials. In some embodiments, the inclusion of an excipient may also improve the handling properties of the dry aerosol-generating material and help the dry aerosol-generating material retain its granular morphology by helping to reduce moisture uptake and increase the resulting cohesiveness of the material. The presence of an excipient may also affect the rate of (freeze) drying.

[0144] Suitable excipients include mannitol, sucrose, trehalose, lactose, sorbitol, raffinose, maltose, dextrans such as dextran 10, dextran 70, dextran 90, maltodextrin, gelatin, agar, cyclodextrin, and polyethylene glycols such as PEG 2000-6000 and polyvinylpyrrolidone (PVP10).

[0145] In some embodiments, the inclusion of one or more excipients, such as dextran 70, in the dry aerosol-forming material may also result in improved handling and reduced water uptake.

[0146] In some embodiments, the aerosol-forming material and / or precursor material includes one or more excipients in an amount of about 0 to about 40% by weight on a wet weight basis, hi some embodiments, the precursor material may include at least about 1%, at least about 10%, at least about 20%, at least about 30%, and / or up to about 40%, up to about 30%, up to about 20%, or up to about 10% by weight of excipients on a wet weight basis.

[0147] In some embodiments, the aerosol-forming material may comprise at least about 0.1%, at least about 10%, at least about 20%, or at least about 25% by weight of excipients (calculated on a dry weight basis). In some embodiments, the aerosol-forming material may comprise up to about 25%, up to about 20%, up to about 15%, or up to about 10% by weight of excipients (calculated on a dry weight basis).

[0148] In an exemplary embodiment, the aerosol-forming material includes, on a dry weight basis, about 36% glycerol, about 45% tobacco extract, and about 19% excipients.

[0149] In another exemplary embodiment, the aerosol-forming material comprises, on a dry weight basis, from about 17 to about 39% glycerol, from about 41 to about 76% tobacco extract, and from 0 to about 28% excipients.

[0150] In embodiments where the excipient is agar, the precursor material may contain 0%, about 5%, or about 10% by weight of agar. The inventors have found that when the precursor material contains a lower concentration of the agar excipient, the agar makes the precursor material more viscous and the freeze-drying process is easier.

[0151] In some embodiments, the precursor material comprises about 50% by weight tobacco extract, 0 to about 36% by weight aerosol forming agent (e.g., 0 to about 15% v / v), and 0 to about 40% by weight excipients (e.g., about 37.5% v / v). The tobacco extract may comprise about 55% by weight tobacco solids, with the total tobacco solids content of the precursor material being about 27.5% by weight.

[0152] In some embodiments, the precursor material comprises about 50% by weight tobacco extract, up to about 36% by weight (e.g., about 15% v / v) glycerol, and 0 to about 40% by weight (e.g., about 37.5% v / v) excipients. The tobacco extract may comprise about 55% by weight tobacco solids, with the total tobacco solids content of the precursor material being about 27.5% by weight.

[0153] Some sample formulations of dry aerosol-forming materials formed from aqueous tobacco extracts are summarized in Table 1 below, with amounts provided on a dry weight basis. These are theoretical values ​​(before drying and inherent losses). Typically, about 80-89% of the glycerol is retained after drying. Glycerol may be used as the aerosol-forming material, but may be replaced or partially replaced with one or more other aerosol-forming materials, such as those disclosed herein. The excipient used may be dextran, e.g., dextran 70. Again, this may be replaced or partially replaced with alternative excipients, such as those disclosed herein.

[0154] [Table 1]

[0155] The nicotine content in the formulation depends on the type of tobacco used and the presence of other components, namely aerosol formers and excipients.

[0156] In some embodiments, the aerosol-generating material and / or the precursor material 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, starches, polysaccharides, pectins, cellulose, cellulose derivatives such as carboxymethylcellulose, and alginates.

[0157] In some embodiments, the aerosol-generating and / or precursor materials include one or more flavor modifiers, flavors, or flavorings, which may be derived from extracts or may be added. As used herein, the terms "flavor" and "flavoring" refer to materials that may be used, where local regulations permit, to create a desired taste, odor, or other somatic sensation in a product intended for adult consumers.They may be any naturally occurring flavoring material, botanical substance, extracts of botanical substances, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherries, berries, red berries, cranberries, peaches, apples, oranges, mangoes, clementines, lemons, Lime, tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, eggplant, betel quid, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, Ylang-ylang, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, peppermint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, bay, yerba mate, orange peel, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, black currant, valerian, pimento, mace, damienne , marjoram, olive, lemon balm, lemon basil, chives, Calvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars 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.They may be of imitation, synthetic, or natural origin, or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas.

[0158] In some embodiments, the flavoring comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavoring comprises cucumber, blueberry, citrus, and / or red berry flavor components. In some embodiments, the flavoring comprises eugenol. In some embodiments, the flavoring comprises flavor components extracted from tobacco. In some embodiments, the flavoring comprises flavor components extracted from cannabis.

[0159] In some embodiments, the fragrance may include a sensory elicitor, which is intended to achieve somatic sensations that are usually chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of the scent or taste nerves, and may include agents that produce a heating, cooling, tingling, or numbing effect. A suitable heating agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol, WS-3.

[0160] In some embodiments, the aerosol-generating material and / or the precursor material include one or more other functional materials, which may include one or more of a pH adjuster, a colorant, a preservative, a filler, a stabilizer, and / or an antioxidant.

[0161] In some embodiments, the aerosol-forming material and / or the precursor material contains a filler component. The filler component is generally a non-tobacco component, i.e., a component that does not contain tobacco-derived raw materials. In some embodiments, the precursor material contains less than 60% filler by weight, such as 1% to 60% by weight, or 5% to 50% by weight, or 5% to 30% by weight, or 10% to 20% by weight on a wet weight basis.

[0162] When present, the filler may include one or more inorganic filler materials such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents such as molecular sieves. The filler may also include one or more organic filler materials such as wood pulp, hemp fiber, cellulose and cellulose derivatives.

[0163] In some embodiments, the dry aerosol-forming material is in the form of a gel. A gelling agent may be added to the aerosol-forming material, the precursor material, or may be optionally omitted. The gelling agent includes one or more compounds selected from cellulosic gelling agents, non-cellulosic gelling agents, guar gum, acacia gum, and mixtures thereof.

[0164] In some embodiments, the cellulosic gelling agent is selected from the group consisting of hydroxymethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose (CMC), hydroxypropylmethylcellulose (HPMC), methylcellulose, ethylcellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP), and combinations thereof.

[0165] In some embodiments, the gelling agent comprises (or is) one or more of hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose (HPMC), carboxymethyl cellulose, guar gum, or acacia gum.

[0166] In some embodiments, the gelling agent comprises (or is) one or more non-cellulosic gelling agents, including, but not limited to, agar, xanthan gum, gum arabic, guar gum, locust bean gum, pectin, carrageenan, starch, alginate, and combinations thereof. In preferred embodiments, the non-cellulosic gelling agent is alginate or agar.

[0167] The aerosol-generating material and / or the precursor material may include an acid. The acid may be an organic acid. In some of these embodiments, the acid may be at least one of a monoprotic acid, a diprotic acid, and a triprotic acid. In some such embodiments, the acid may contain at least one carboxyl functional group. In some such embodiments, the acid may be at least one of an alpha-hydroxy acid, a carboxylic acid, a dicarboxylic acid, a tricarboxylic acid, and a keto acid. In some such embodiments, the acid may be an alpha-keto acid.

[0168] In some such embodiments, the acid may be at least one of succinic acid, lactic acid, benzoic acid, citric acid, tartaric acid, fumaric acid, levulinic acid, acetic acid, malic acid, formic acid, sorbic acid, benzoic acid, propanoic acid, and pyruvic acid. In some embodiments, the acid is selected from one of lactic acid, benzoic acid, and levulinic acid.

[0169] In other embodiments, the acid may be an inorganic acid. In some of these embodiments, the acid may be a mineral acid. In some such embodiments, the acid may be at least one of sulfuric acid, hydrochloric acid, boric acid, and phosphoric acid.

[0170] The inclusion of an acid can be beneficial in embodiments in which the aerosol-generating material and / or precursor material includes nicotine. In such embodiments, the presence of an acid can stabilize dissolved species in the slurry from which the aerosol-generating material is formed. The presence of an acid can reduce or substantially prevent evaporation of nicotine during drying of the slurry, thereby reducing loss of nicotine during production.

[0171] In certain embodiments, the aerosol forming material comprises a gelling agent comprising a cellulosic and / or non-cellulosic gelling agent, an active agent, and an acid.

[0172] The dry aerosol-generating material may be in any solid form. For example, the aerosol-generating material may be in the form of particles, granules, or powder. The aerosol-generating material may be in monolithic form, tablet, agglomerate, or "cake" form. In some embodiments, the aerosol-generating material is formed by freeze-drying or spray-drying, and then processed as necessary by other suitable steps known to those skilled in the art to provide the dry material in the desired form, e.g., in the form of particles of the desired size(s).

[0173] In some embodiments, the aerosol-generating material is in the form of granules. The granules can be of any size, cross-sectional shape, or mass. Aerosol-generating materials in the form of granules are advantageous due to their high surface area to volume ratio, which positively impacts the release of volatile substances from the material. This form also facilitates the incorporation of the material into an aerosol delivery system.

[0174] In some embodiments, the aerosol-forming material is free-flowing and non-sticky, which aids in further processing and handling of the aerosol-forming material.

[0175] Smaller granule particles have a greater surface area to volume ratio and therefore may exhibit enhanced release of tobacco constituents as compared to larger sized particles.

[0176] In some embodiments, the particles in the precursor composition have an average particle size of about 3 mm or less, 1 mm or less, about 0.5 mm or less, or desirably about 0.3 mm or less, as measured by sieving.

[0177] In some embodiments, the average particle size is within 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 within 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 tobacco particles of the precursor composition have a particle size within the range of about 0.1 to about 3 mm, or about 0.1 to about 1 mm, or about 0.1 to 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. In some embodiments, the average particle size is less than 1 mm.

[0178] When preparing the dried precursor composition, the particle size of any solid material present can be reduced by grinding, shredding, cutting or crushing the plant material. Suitable machines for making such plant particles include, for example, shredders, cutters, or mills, such as hammer mills, roller mills or other types of commercially available milling machines. The size of the plant particles is selected to result in particles that can be readily prepared from a variety of different types of plant material having the characteristics described herein and that provide a source of readily releasable plant components.

[0179] Smaller size particles of the aerosol-generating material may be advantageous for aerosol generation. Without wishing to be bound by any particular theory, smaller particles may have a larger surface area to volume ratio, which may improve aerosol generation. In some embodiments, the dry aerosol-generating material readily forms particles having an average size of less than 1 mm. In some embodiments, the particles may be as small as 10 μm, or as small as 1 μm. The size of the particles may be determined by sieving or by observing the particles with a SEM.

[0180] In some embodiments, the lyophilized precursor material can be ground into particles and sieved to remove particles that are deemed too small or too large for use as an aerosol generating material.

[0181] In some embodiments, the aerosol-generating material used in the present invention has a particle size distribution D10 of about 5 to about 25 μm (meaning that 10% of the particles in the test sample are smaller than the value), a particle size distribution D50 of about 30 to about 200 μm (meaning that 50% of the particles in the test sample are smaller than the value), and a particle size distribution D90 of about 500 to about 2500 μm (meaning that 90% of the particles in the test sample are smaller than the value). These values ​​are determined using a particle size analyzer, Microtrac CamSizer® X2. The percentages referred to herein are volume percentages.

[0182] In some embodiments, the lyophilized material used as an aerosol generating material according to the present invention has a particle size distribution, D10, of about 8 to about 15 μm, a particle size distribution, D50, of about 50 to about 150 μm, and a particle size distribution, D90, of about 900 to about 1700 μm.

[0183] In some embodiments, the D10 average is from about 10 to about 15 μm, the D50 average is from about 40 to about 140 μm, and the D90 average is from about 800 to about 1600 μm.

[0184] Spray drying and freeze drying The drying method used to dry the precursor material can be any suitable drying process, including freeze-drying or spray-drying processes. The drying process used must be compatible with the desired composition of the precursor material and the aerosol-forming material. Because it may be desirable for the aerosol-forming material to contain actives and / or flavorings from extracts in the precursor material, it is important to select a drying method that retains sufficient amounts of these components.

[0185] In a small scale example, the precursor material is freeze-dried using a freeze-drying microscope, for example a Lyostat freeze-drying microscope.

[0186] In the spray drying process, precursor material is atomized and dried rapidly using hot gas. The use of spray drying provides several advantages to the present invention, such as the dried particle size can be controlled and consistent, tobacco or flavor extracts or materials are heat sensitive but can still be spray dried at relatively high inlet temperatures, short residence times are required in the spray drying equipment, and loss of flavor / volatiles is minimal. This makes the process adaptable to reduce loss of volatile compounds and maintain the desired flavor of the aerosol-generating material.

[0187] Lyophilization, also known as cryodesication, is a process in which precursor materials are frozen, the temperature is reduced, and water is removed by sublimation under reduced pressure conditions. Without wishing to be bound by any particular theory, it is believed that the low processing temperature and rapid water loss by sublimation avoids changes in the structure, appearance and properties of the aerosol-forming material. This process preserves the structure of the precursor materials and reduces the loss and decomposition of volatile flavor compounds.

[0188] The dry aerosol-forming material has a lower water content than the precursor material. The water content of the aerosol-forming material may be up to about 0.5%, about 1%, about 2%, about 5%, about 10%, or about 20% by weight (calculated on a wet weight basis). The water content of the dry aerosol-forming material may be reduced by at least about 50%, about 60%, about 70%, about 80%, about 90%, about 95%, about 98%, or about 100% by weight from the precursor material. In some embodiments, the dry aerosol-forming material has a water content of less than about 5%, less than about 4%, less than about 3%, less than about 2%, or less than about 1% by weight (calculated on a wet weight basis) as measured by gas chromatography-thermal conductivity detector (GC-TCD) or Karl Fischer titration.

[0189] In an exemplary embodiment of the invention, the precursor material comprises Burley tobacco extract and has a moisture content of 60% by weight. After the freeze-drying operation described herein, the dry aerosol-forming material has a moisture content of 3% by weight.

[0190] A lower moisture content of the dry aerosol-generating material is associated with shelf life and stability. However, a very low moisture content may be associated with a brittle structure and smaller particle size, as well as longer processing times. The material is also very hygroscopic. On the other hand, if the moisture content of the dry aerosol-generating material is too high, the desired stability improvement may not be achieved. The dry aerosol-generating material is also not easy to handle at higher moisture contents, and the material may become sticky.

[0191] The inventors have found that when a precursor material includes an excipient, the precursor material may be more suitable for drying by spray drying (compared to a precursor material that does not include an excipient). Without wishing to be bound by any particular theory, it is speculated that increasing the amount of excipient in the precursor material increases the glass transition temperature above 100° C., which affects the physical properties of the material making it more suitable for spray drying.

[0192] ingredient composition In some embodiments, the component consists or consists essentially of a dry aerosol-generating material, while in other embodiments, the component consists or consists essentially of a dry aerosol-generating material and one or more aerosol-forming materials.

[0193] In other embodiments, the component may include one or more additional materials in addition to the aerosol-generating material and any additional aerosol-forming materials.

[0194] In some embodiments, a second, different aerosol-generating material may be included in the component. For example, the second aerosol-generating material may include a tobacco material. In some embodiments, particles of tobacco may be blended with a dry aerosol-generating material and formed into the component. Additionally or alternatively, the second aerosol-generating material may include a gel or dry gel that includes one or more active and / or flavoring substances, an aerosol-forming material, and a gelling agent.

[0195] In some embodiments, the component includes a heating material, which is optionally in direct contact with the aerosol-generating material.

[0196] The heating material may include one or more materials selected from the group consisting of an electrically conductive material, a magnetic material, and a magnetically conductive material. In some embodiments, the heating material may include a metal or metal alloy. In some embodiments, the heating material may include one or more materials selected from the group consisting of aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite, plain carbon steel, stainless steel, ferritic stainless steel, copper, and bronze.

[0197] In some embodiments, the heating material may be heated by induction heating, a process in which a conductive object is heated by penetrating a varying magnetic field into the conductive object. In some embodiments, the heating material may be heated by resistive heating. In such embodiments, the heating material is connected to a power source. Alternatively, the heating may be microwave heating or infrared heating.

[0198] The heating material may be provided in the form of a plurality of particles embedded within or disposed on a surface of the component. In other embodiments, the heating material is planar or substantially planar, for example in the form of a flat strip, ribbon, or mesh. Alternatively, the heating material may be non-planar. For example, the heating material may follow a wavy or corrugated path, may be twisted, corrugated, helical, spiral, may comprise a plate or strip or ribbon having protrusions thereon and / or depressions therein, may comprise a mesh, may comprise expanded metal, or may have a non-uniform non-planar shape.

[0199] In some embodiments, the additional component material(s) may be functional materials such as one or more selected from the group consisting of binders, excipients, diluents, flavor modifiers, disintegrants, pH adjusters, and the like.

[0200] These materials are generally included to provide the component with desired properties. For example, in some embodiments, a porous diluent may be included in the component to increase the porosity of the component and aid in the release of the aerosol generated by heating the aerosol-generating material.

[0201] Moisture-proof In some embodiments, the components further include a material that prevents or reduces absorption of moisture by the dry aerosol-forming material.

[0202] In some embodiments, the components and / or hygroscopic aerosol-forming materials have a water content of about 10% or less or about 5% or less (calculated on a wet weight basis) as measured by gas chromatography-thermal conductivity detector (GC-TCD) or Karl Fischer titration. This water content is stable, meaning that the water content of the aerosol-forming material is within this range not only when the aerosol-forming material is first prepared, but also after incorporation into an aerosol product, transportation, and storage. This stable water content is observed despite the fact that the hygroscopic aerosol-forming material rapidly absorbs moisture when exposed to the environment, even under "normal" humidity conditions. Indeed, when an aerosol-forming material is described as hygroscopic, this means that it rapidly absorbs water from the surrounding environment, significantly increasing its water content. For example, when the aerosol-forming material is exposed to the environment (e.g., upon storage in an open container, etc.), the water content rapidly increases to more than 20% or more than 25% (calculated on a wet weight basis) as measured by gas chromatography-thermal conductivity detector (GC-TCD) or Karl Fischer titration.

[0203] In some embodiments, the components disclosed herein further include a moisture impermeable coating surrounding the aerosol-forming material, the coating creating a moisture impermeable barrier around the dry aerosol-forming material.

[0204] The physical and chemical properties of the coating material are important. In addition to forming a moisture-impermeable coating, the coating must also be stable and remain in place during the period between manufacture and use by the consumer. In some embodiments, it is desirable for the moisture-impermeable coating to become moisture-permeable when the aerosol-generating material is heated to generate an aerosol. This is necessary to ensure that the aerosol can be released. In some embodiments, the coating is made moisture-permeable by melting or other decomposition of the coating material or at least a portion of the coating.

[0205] In some embodiments, degradation of the coating involves the coating losing its physical integrity such that it no longer forms a barrier around the aerosol-generating material, which may involve, for example, melting, disappearing, disintegrating, or otherwise decomposing the coating.

[0206] It may be expected that the integrity of the moisture-impermeable coating may be compromised when the coating material is heated to its melting point. Thus, the coating material should be selected so that the moisture-impermeable coating remains intact when exposed to normal environmental temperatures. Thus, in some embodiments, the coating material used must be one that forms a stable moisture-impermeable coating at temperatures below 40 or 50° C. In some embodiments, it may be desirable to select a coating material that forms a moisture-impermeable coating that remains intact during the more extreme temperatures that may be encountered during storage and transportation, for example, temperatures between 60 and 80° C.

[0207] In some embodiments, to avoid overheating of moisture present in the coated aerosol-generating material, a moisture-impermeable coating can become moisture-permeable when the temperature is raised to about 100-110° C. In some embodiments, the coating opens rapidly upon heating to form an aerosol. This reduces the likelihood that the coating will impede volatilization and the resulting release of gas or vapor.

[0208] In some embodiments, the temperature at which a moisture impermeable coating becomes moisture permeable, for example as a result of decomposition, is at least about 50°C, at least about 60°C, at least about 70°C, at least about 80°C, at least about 90°C, at least about 100°C, at least about 110°C, at least about 120°C, at least about 130°C, at least about 140°C, at least about 150°C, at least about 160°C, at least about 170°C, at least about 180°C, at least about 190°C, or at least about 200°C.

[0209] Additionally or alternatively, the temperature at which a moisture impermeable coating becomes moisture permeable, for example as a result of decomposition, is about 280°C or less, about 270°C or less, about 260°C or less, about 250°C or less, about 240°C or less, about 230°C or less, about 220°C or less, about 210°C or less or 200°C or less, about 190°C or less, about 180°C or less, about 170°C or less, about 160°C or less, about 150°C or less, about 140°C or less, about 130°C or less, about 120°C or less, about 110°C or less, or about 100°C or less.

[0210] In some embodiments, the moisture impermeable coating comprises one or more materials selected from polysaccharide or cellulosic materials or derivatives thereof, gums, protein materials, polyol matrix materials, waxes, wax esters, and polymers.

[0211] Suitable polysaccharides include, for example, agar, agarose, pectin, freudan, furcellan, alginate, carrageenan, starch, dextran, maltodextrin and cyclodextrin. Suitable cellulose-based materials include, for example, methylcellulose, ethylcellulose, hydroxypropylcellulose, carboxymethylcellulose, hydroxypropylmethylcellulose (HPMC), hydroxyethylcellulose (HEC), cellulose acetate butyrate (CAB), cellulose acetate phthalate (CAP), cellulose acetate trimellitate (CAT) and cellulose acetate succinate (CAS), and cellulose ethers. Suitable modified starches include, for example, high amylose starch, hydroxypropylated starch, octenyl succinate modified starch, starch esters and starch-based polyelectrolyte complexes (SPEC). Suitable gums include, for example, gum arabic (acacia gum), guar gum, karaya gum, tragacanth gum, ghatti gum, quince seed gum, locust bean gum, and xanthan gum. Suitable proteins include zein and gelatin. Suitable polyol matrices may be formed from polyvinyl alcohol. Suitable waxes include, for example, palmitic acid, carnauba wax, beeswax, candelilla wax, and paraffin wax. Suitable wax esters include, for example, cetyl palmitate and triacontanyl palmitate. Suitable polymers include, for example, shellac, lignin, polyvinyl alcohol, polyurethane, polymerized, hydrolyzed ethylene vinyl acetate, polyester, polycarbonate, polymethacrylate, polyglycol, polyethylene, polystyrene, polypropylene, and polyvinyl chloride. Suitable copolymers include, for example, methacrylic acid copolymers and acrylic acid copolymers.

[0212] In some embodiments, the coating material comprises an additive that is released when the component is heated, and thus contributes to the aerosol generated.For example, the coating material may comprise an active material, including one or more of the active materials described elsewhere herein.In addition or alternatively, the coating material may comprise a flavoring, including one or more of the flavorings and flavorings described elsewhere herein.In some embodiments, the flavoring added to the coating is a hydrophobic flavoring.This may mean that the flavoring further enhances the moisture impermeability of the coating.

[0213] Since the intent of the coating is to prevent or retard the adsorption of moisture by the aerosol-forming material, in some embodiments the moisture impermeable coating completely encapsulates the aerosol-forming material. Although an incomplete coating may retard moisture absorption sufficiently to provide some benefit, in preferred embodiments the coating should cover at least 80%, at least 90%, at least 95%, or at least 99% of the surface area of ​​the aerosol-forming material.

[0214] In some embodiments, the moisture impermeable coating prevents the dry aerosol-forming material from absorbing moisture from the surrounding environment.

[0215] Ideally, the coating is thick enough to impart the desired moisture impermeability, which in some embodiments further influences the temperature at which the coating becomes moisture permeable, allowing volatile components generated by heating the dry aerosol-forming material to be released from the component.

[0216] In some embodiments, the thickness of the coating can also affect the rate at which the coating becomes moisture permeable once exposed to decomposition temperatures, which can allow for control of the release rate of volatile components from the heated aerosol-forming material.

[0217] In some embodiments, the moisture impermeable coating has a thickness of about 1 μm to about 100 μm.

[0218] In some embodiments, the coating thickness is at least about 1 μm, at least about 5 μm, at least about 10 μm, at least about 15 μm, at least about 20 μm, at least about 25 μm, at least about 30 μm, at least about 35 μm, or at least about 40 μm. Additionally or alternatively, the coating thickness is at most about 100 μm, at most about 90 μm, at most about 80 μm, at most about 75 μm, at most about 70 μm, at most about 65 μm, at most about 60 μm, at most about 55 μm, at most about 50 μm, at most about 45 μm, or at most about 40 μm. In some embodiments, the coating thickness is about 5 to about 50 μm.

[0219] For some materials, the minimum thickness of the coating may be determined by the thickness necessary to ensure that the coating is moisture impermeable or sufficiently moisture impermeable to protect the enclosed aerosol-generating material. For some materials, the maximum thickness of the coating may be determined by the time necessary to ensure that the coating is open enough to allow the vapor or aerosol generated by heating the aerosol-generating material to be generated and released. For this reason, thicker coatings may be less preferred in some embodiments.

[0220] In some embodiments, the thickness of the moisture impermeable coating applied to a component containing an aerosol-generating material may be substantially uniform, for example, varying by no more than 20%, 15%, 10%, or 5%.

[0221] In other embodiments, the thickness of the moisture impermeable coating applied to a component or portion of a component may vary by 50% or more. In some embodiments, this results in a coating that does not degrade uniformly. For example, areas where the coating is thinner may tend to degrade faster. This may help to achieve a more gradual and sustained release of the aerosol generated by heating the component containing the aerosol-generating material.

[0222] In some embodiments, the composition comprises multiple components, each coated with the same material. Additionally or alternatively, the composition comprises multiple components, each coated with the same thickness of coating.

[0223] In other embodiments, the composition comprises multiple components, including at least two components coated with different coating materials. Additionally or alternatively, the composition comprises multiple components, including at least two components having coatings of different thicknesses.

[0224] To control the release of volatiles from the aerosol-generating material upon heating, in some embodiments, coatings of different components of the aerosol-generating material can decompose at different temperatures or at different rates to control the release of volatile components generated by heating the dry aerosol-generating material.

[0225] In some embodiments, sustained and controlled release of a volatile component can be achieved by a composition that includes separate components of dry aerosol-forming material surrounded by coatings of different thicknesses.

[0226] Alternatively or additionally, sustained and controlled release of the volatile component may be achieved by having a composition comprising separate components of a dry aerosol-forming material surrounded by a coating of a distinct coating material.

[0227] Thus, the components disclosed herein can be formulated with coatings to provide a predictable and consistent release of the active and / or fragrance compounds upon heating and over the course of a heating session, meaning that the aerosol generating system can reliably provide a consistent aerosol regardless of the length of time the components have been stored or the conditions under which they have been stored prior to use.

[0228] In some embodiments, the component containing the aerosol-forming material has a desired size and shape before the moisture impermeable coating is applied.

[0229] In some embodiments, the components comprising the aerosol-forming material have a size (as measured by sieving) of from about 1 mm to about 20 mm, optionally from about 1 mm to about 4 mm.

[0230] The coating can be applied to the component using any conventional coating process, for example, the aerosol-generating material may be coated by spray coating, gas aerosolized coating, tumbling (or rumble) coating in a rotating drum, or a fluidized bed coating process by immersion in a bath of the coating material.

[0231] In some embodiments, the coating is applied directly to the surface of the aerosol-generating material. The coating may be applied to the surface of a component or to the surface of a material that comprises a component (i.e., applied to the material before it is formed into a component).

[0232] In some embodiments, the coating is applied to the surface of the aerosol-generating material in the form of a powder. In such embodiments, the average particle size of the coating powder is from about 100 nm to about 50 μm. In some embodiments, the average particle size of the coating powder is at least about 100 nm, at least about 200 nm, at least about 300 nm, at least about 400 nm, at least about 500 nm, at least about 600 nm, at least about 700 nm, at least about 800 nm, at least about 900 nm, at least about 1 μm, at least about 2 μm, at least about 3 μm, at least about 4 μm, at least about 5 μm, at least about 10 μm, at least about 15 μm, at least about 20 μm, at least about 25 μm, at least about 30 μm, at least about 35 μm, or at least about 40 μm.

[0233] Additionally or alternatively, the average particle size of the coating powder is about 50 μm or less, about 45 μm or less, about 40 μm or less, about 35 μm or less, about 30 μm or less, about 25 μm or less, about 20 μm or less, about 15 μm or less, about 10 μm or less, about 5 μm or less, about 4 μm or less, about 3 μm or less, about 2 μm or less, or about 1 μm or less.

[0234] In some embodiments, the coating adheres to the surface of the aerosol-generating material by inter-particle forces, such as van der Waals forces. In some embodiments, the surface of the aerosol-generating material is sticky, such that particles of the coating material adhere easily to the surface to form a complete or substantially complete coating. The stickiness of the aerosol-generating material can be adjusted by adjusting the moisture content of the aerosol-generating material at the time the coating is applied.

[0235] In some embodiments, the moisture impermeable coating is formed as part of a spray drying or freeze drying process. For example, the moisture impermeable coating former may be included in the precursor material and form the coating when the precursor material dries. This may require that the aerosol-forming material and the coating material have chemical properties that ensure the coating material migrates to the surface of the dried material such that it surrounds the dried aerosol-forming material. For example, in some embodiments, the coating material is a non-polar and / or hydrophobic material that may be included in the precursor material that is dried. Once these coated particles are formed by the drying process, they can be used to form the components discussed herein.

[0236] As mentioned above, the moisture-impermeable coating has the advantage of protecting the aerosol-generating material from moisture and the adverse effects it may have on the material and the aerosol generated when heated. The coating can also control the release of the aerosol generated by heating the aerosol-generating material, as mentioned above. In addition, there are other advantages provided by the coatings described herein. The aerosol-generating material may be sticky or tacky. This can make the material difficult to process and handle. A coating applied to the surface of the aerosol-generating material covers this tackiness, making the composition easier to process and handle. As a result, it may be preferable to add the coating after the component is formed.

[0237] Coatings can also increase the structural integrity of the aerosol-generating material: they provide additional support and strength to the components, reducing their tendency to break down and form dust that can be harmful to the products and machines used to manufacture the components.

[0238] In an alternative or additional approach to protecting the aerosol-forming material from moisture, the components described herein include an adsorbent material that is intended to absorb or adsorb moisture from the environment, thus reducing the exposure of the aerosol-forming material to moisture, and therefore reducing absorption of moisture by the aerosol-forming material prior to its use.

[0239] Competition for moisture between the aerosol-forming material and the adsorbent material means that the amount of moisture absorbed by the aerosol-forming material is reduced: the higher the affinity of the adsorbent for water, the more moisture the adsorbent will adsorb or absorb, and the less moisture will be available for the aerosol-forming material to absorb.

[0240] In some embodiments, the adsorbent material is more hygroscopic than the aerosol-generating material. For example, dynamic vapor sorption (DVS) is a gravimetric method that can be used to measure the rate at which a sample of material absorbs water by varying the water vapor concentration surrounding the sample and measuring the resulting change in mass. DVS can be used to measure the water absorption rates of both the adsorbent material and the aerosol-generating material. In preferred embodiments, the water absorption rate of the adsorbent material is preferably faster than the water absorption rate of the aerosol-generating material.

[0241] In particular, the water absorption rate of the adsorbent material is preferably at least about 20% RH, at least about 30% RH, at least about 40% RH, or at least about 50% RH faster than the water absorption rate of the aerosol-forming material.

[0242] In some embodiments, the sorbent material not only absorbs or adsorbs moisture, but also prevents the release of this water (as vapor) in a manner that may impede the desired aerosol generated by heating the aerosol-generating material. Thus, in some embodiments, the sorbent retains the captured moisture while the aerosol-generating material is heated to form the aerosol. Thus, in some embodiments, the sorbent material retains the absorbed or adsorbed moisture at temperatures up to about 200° C., up to about 250° C., up to about 300° C., up to about 325° C., or up to about 350° C. In other embodiments, the sorbent releases water at temperatures between about 100° C. and about 150° C., thereby releasing water at a temperature below the temperature at which the first puff of aerosol is generated for inhalation by the consumer.

[0243] In some embodiments, the adsorbent material is a desiccant.

[0244] Suitable adsorbent materials may include one or more selected from the group consisting of silica gel, molecular sieves, activated carbon, zeolites, sodium acrylate, and simple salts such as alkaline earth metal or alkali metal salts, carbonates and hydroxides, carbonates and hydrides, such as calcium chloride, sodium chloride, magnesium sulfate, potassium carbonate, and sodium hydroxide. These adsorbent materials are suitable for inclusion in compositions that are heated to generate aerosols for inhalation by consumers. In some embodiments, the adsorbent material is stable at the temperatures to which the composition is exposed when heated to generate aerosols. Thus, in such embodiments, the adsorbent does not decompose, melt, or otherwise disintegrate when exposed to high temperatures during use of the composition.

[0245] In some embodiments, the component includes an adsorbent material on its surface. For example, the adsorbent material may form a partial or incomplete coating surrounding the component. A partial or incomplete coating means that the aerosol generated by heating the aerosol-generating material can be released from the component and is available for inhalation. In some embodiments, the partial coating is in the form of a permeable network. This ensures that the adsorbent is present on the surface of the component, but does not prevent the volatile substances generated by heating the aerosol-generating material from being released.

[0246] If the adsorbent material swells upon absorbing moisture, it may be desirable to provide a coating that does not result in complete coating as a result of swelling of the adsorbent material. Thus, in some embodiments, it may be desirable for the adsorbent coating to be sufficiently incomplete to ensure that the aerosol-generating material is exposed and may not end up completely surrounded by the adsorbent material.

[0247] In some embodiments, the component includes an adsorbent material in the form of particles. These particles may be included, for example, with the aerosol-generating material in the component. In some embodiments, the adsorbent and the aerosol-generating material are homogenously mixed in the component. In other embodiments, particles of the adsorbent are not included in the component. In some embodiments, the adsorbent particles can be concentrated in one or more locations to increase exposure to ambient moisture. This may mean that moisture is more easily absorbed or adsorbed by the adsorbent material than by the aerosol-generating material.

[0248] In some embodiments, the components include one or more sorbent particles or granules, hi some embodiments, the sorbent particles have an average size of at least about 50 nm, at least about 100 nm, at least about 200 nm, at least about 500 nm, at least about 1 μm, at least about 10 μm, at least about 50 μm, at least about 100 μm, at least about 200 μm, at least about 500 μm, at least about 600 μm, at least about 700 μm, at least about 800 μm, at least about 900 μm, or at least about 1 mm.

[0249] Additionally or alternatively, the sorbent particles have an average size of about 3 mm or less, about 2.5 mm or less, about 2 mm or less, about 1.5 mm or less, about 1 mm or less, about 900 μm or less, about 800 μm or less, about 700 μm or less, about 600 μm or less, or about 500 μm or less.

[0250] In some embodiments, the amount of adsorbent material included in or on the surface of the component is at least about 5%, at least about 10%, at least about 15%, at least about 20%, at least about 25%, or at least about 30% based on the total weight of the component. Alternatively or additionally, the amount of adsorbent material included in the component is no more than about 50%, no more than about 45%, no more than about 40%, no more than about 35%, no more than about 30%, no more than about 25%, or no more than about 20% based on the total weight of the component.

[0251] In some embodiments, the amount of adsorbent included is from about 5 to about 40% by weight of the component, or from about 10 to 30% by weight of the component.

[0252] The amount of sorbent that can be included can be limited by the potential swelling of the sorbent material as it absorbs moisture. This increase in size of the sorbent increases the volume of the aerosol generating material and the component that contains the sorbent material. In extreme situations where large amounts of sorbent are included in the composition and in an environment with high moisture levels, the swelling of the sorbent can cause problems such as the consumable no longer fitting into the aerosol delivery device or the airflow through the component is reduced, compromising the release of the aerosol.

[0253] Use of the composition Components containing aerosol-forming materials can be used in combustion or non-combustion aerosol delivery systems, or in aerosol-free delivery systems.

[0254] In other embodiments, the components are formed to transport and store the aerosol-generating material, but then the components are converted to a different form, such as a free-flowing powder, prior to use in the delivery system. In some embodiments, the components may be disintegrated prior to or during incorporation into the consumable. In other embodiments, the components may be disintegrated upon insertion of the component into a delivery device or immediately prior to use of the component in a delivery device.

[0255] The present invention also relates to consumables or articles that include components that contain aerosol-forming materials, including dried precursor materials that include extracts derived from perfume-containing and / or active-containing plant materials.

[0256] In some embodiments, the components are provided within or as a consumable.

[0257] A consumable is an article that contains an aerosol-generating material, some or all of which is intended to be consumed during use by a user, where the aerosol-generating material, or at least a portion of the aerosol-generating material, is in the form of one or more components disclosed herein.

[0258] The consumable may include one or more other items, such as an aerosol-generating material storage area, an aerosol-generating material transport component, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and / or an aerosol modifier. The consumable may also include an aerosol generator, such as a heater that generates heat during use to cause the aerosol-generating material to generate an aerosol. The heater may include, for example, a combustible material, a material heatable by electrical conduction, or a susceptor. The consumable may be of any shape or size suitable for a smoking device. In one embodiment, the consumable is rod-shaped.

[0259] In some embodiments, the component comprising the aerosol-generating material is provided in an aerosol-generating device, such as a tobacco heating product (THP) or a hybrid e-cigarette product. Suitably, the component may be used directly as a solid substrate, where the component is heated directly without combustion to provide an inhalable aerosol.

[0260] In some embodiments, the components including the aerosol-forming materials may be incorporated into the consumable without a carrier or other substrate material that needs to be heated.

[0261] In some embodiments, the total mass of dry aerosol-forming material included for use in the delivery system is up to about 200 mg, up to about 190 mg, up to about 180 mg, up to about 170 mg, up to about 160 mg, up to about 150 mg, up to about 140 mg, up to about 130 mg, up to about 120 mg, up to about 110 mg, up to about 100 mg, up to about 90 mg, up to about 80 mg, up to about 70 mg, up to about 60 mg, or up to about 50 mg.

[0262] Alternatively or additionally, the total mass of dry aerosol-forming material included may be at least about 5 mg, at least about 10 mg, at least about 15 mg, at least about 20 mg, at least about 25 mg, at least about 30 mg, at least about 35 mg, at least about 40 mg, at least about 45 mg, or at least about 50 mg.

[0263] In some embodiments, the total mass of dry aerosol generating material is sufficient to provide, for example, up to about 10 puffs of aerosol generated in a single session or over a series of multiple sessions, in such embodiments, the total mass of dry aerosol generating material provided is about 10 to 100 mg, or about 25 to about 50 mg.

[0264] In some embodiments, the consumable includes a moisture impermeable coating that surrounds the aerosol-generating material, but may be separate from the aerosol-generating material. For example, the moisture impermeable coating may surround a component (thereby surrounding the aerosol-generating material within the component). In some embodiments, the moisture impermeable coating may be provided as a film or wrapper, and may optionally be deposited on a moisture permeable carrier.

[0265] In some embodiments, the consumable includes a sorbent or desiccant material. As mentioned above, the sorbent or desiccant material can be provided within the component. Alternatively, the sorbent or desiccant material may be provided separately within the consumable, but in such a way that the sorbent still competes with the aerosol-generating material for moisture in the environment, thus reducing the amount of moisture absorbed by the aerosol-generating material. In some embodiments, the sorbent may be provided in or on a wrapper that surrounds the aerosol-generating material within the consumable. In other embodiments, the sorbent may be incorporated into a separate section of the consumable relative to the aerosol-generating material. This may have the advantage of reducing exposure of the sorbent to high temperatures to which the aerosol-generating material is heated during use. For example, the sorbent may be located in an adjacent section of the consumable that is not directly heated. This may be downstream or upstream of the aerosol-generating material. In some embodiments, the sorbent is included in one or more sections of the consumable that do not include the aerosol-generating material, such as a cooling element section or a filter section.

[0266] In yet another embodiment, the sorbent may be separated or removed from the aerosol-generating material and / or consumable prior to use. For example, the sorbent may be disposed within the packaging in which the consumable is held prior to use. In some embodiments, the packaging may be a wrapper, box, or other container. The sorbent may be incorporated into the packaging material or part thereof. Alternatively, the sorbent may be provided in a separate article, such as a sachet or sheet, that is placed with the consumable within the packaging.

[0267] Delivery System The delivery systems described herein can be combustion aerosol delivery systems, non-combustion aerosol delivery systems, or aerosol-free delivery systems.

[0268] As used herein, the term "delivery system" is intended to encompass a system that delivers at least one substance to a user, Combustion aerosol delivery systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for roll-your-own or hand-made cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes, or other smokable materials); non-combustion aerosol delivery systems that release compounds from an aerosol-forming material without burning the aerosol-forming material, such as electronic cigarettes, tobacco heating products, and hybrid systems that generate aerosols using a combination of aerosol-forming materials; and An aerosol-free delivery system that delivers at least one substance to a user orally, nasally, transdermally, or otherwise without forming an aerosol, including, but not limited to, oral products such as lozenges, gums, patches, articles containing inhalable powders, and oral tobacco, including snus or moist snuff, where the at least one substance may or may not contain nicotine. Includes.

[0269] According to the present disclosure, a "combustion-based" aerosol delivery system is a system in which the constituent aerosol-generating materials (or components thereof) of the aerosol delivery system are combusted or burned during use to facilitate delivery of at least one substance to a user.

[0270] In some embodiments, the delivery system is a combustion aerosol delivery system, such as a system selected from the group consisting of a cigarette, a cigarillo, and a cigar.

[0271] In some embodiments, the present disclosure relates to components for use in combustion aerosol delivery systems, for example, aerosol modifier-releasing components such as filters, filter rods, filter segments, tobacco rods, spills, capsules, threads or beads, or papers such as plug wrap, tipping paper or cigarette paper.

[0272] According to the present disclosure, a "non-combustion" aerosol delivery system is one in which the constituent 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.

[0273] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0274] In some embodiments, the non-combustion aerosol delivery system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0275] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. One example of such a system is a tobacco heating system.

[0276] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates an aerosol using a combination of aerosol-generating materials, one or more of which may be heated and may be components that include the aerosol-generating materials described herein. 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 includes 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.

[0277] 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.

[0278] In some embodiments, the present disclosure relates to consumables that include one or more components that contain an aerosol generating material and are configured for use with a non-combustion aerosol delivery device. These consumables may be referred to as articles throughout this disclosure.

[0279] In some embodiments, the non-combustion aerosol delivery system, such as the non-combustion aerosol delivery device, may include a power source and a controller. The power source may be, for example, a power source or a heat generating power source. In some embodiments, the heat generating power source includes a composition including an agglomerate including a plurality of particles of the aerosol generating material or a carbon substrate that can be energized to deliver power in the form of heat to a heat transfer material proximate to the heat generating power source.

[0280] In some embodiments, the non-combustion aerosol delivery system may include a receiving region, an aerosol generator, an aerosol-generating region, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0281] In some embodiments, consumables for use with non-combustion aerosol delivery devices may include a component containing an aerosol-generating material, an aerosol-generating material storage region, an aerosol-generating material transport component, an aerosol generator, an aerosol-generating region, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0282] 1 is a side cross-sectional view of a consumable or article 1 for use in an aerosol delivery system. The article 1 comprises a mouthpiece segment 2 and an aerosol generation segment 3.

[0283] The aerosol-generating segment 3 is in the form of a cylindrical rod and contains a composition 4 that includes one or more components that include an aerosol-generating material. The components can be any of the components discussed herein.

[0284] Although described above in rod form, the aerosol-generating segment 3 may be provided in other forms, for example as a plug, pouch, or packet of material within the article.

[0285] The tipping segment 2, in the illustrated embodiment, includes a body of material 5, such as fibrous or filamentary tow.

[0286] The rod-shaped consumable 1 further comprises a wrapper 6 , for example a wrapping paper, circumscribing the mouthpiece segment 2 and the aerosol-generation segment 3 .

[0287] 2 shows an example of a non-combustion aerosol delivery device 100 for generating an aerosol from an aerosol-generating medium / material, such as a composition of a consumable product 110, as described herein. Generally, device 100 may be used to heat a replaceable article 110 comprising an aerosol-generating medium, such as article 1 as described in FIG. 1 or elsewhere herein, to generate an aerosol or other inhalable medium that is inhaled by a user of device 100. Device 100 and replaceable article 110 together form a system.

[0288] The device 100 comprises a housing 102 (in the form of an outer cover) that surrounds and contains the various components of the device 100. The device 100 has an opening 104 in one end through which an item 110 can be inserted for heating by a heating assembly. In use, the item 110 can be fully or partially inserted into the heating assembly where it can be heated by one or more components of the heater assembly.

[0289] The device 100 in this example includes a first end member 106 that includes a lid 108 that is movable relative to the first end member 106 to close the opening 104 when the article 110 is not in place. In Figure 2, the lid 108 is shown in an open configuration, but the lid 108 may be moved to a closed configuration. For example, a user may slide the lid 108 in the direction of arrow "B."

[0290] Device 100 may also include user-operable controls 112, such as buttons or switches that, when pressed, operate device 100. For example, a user may turn device 100 on by operating switch 112.

[0291] The device 100 may also include an electrical component, such as a socket / port 114 that can accept a cable for charging a battery of the device 100. For example, the socket 114 may be a charging port, such as a USB charging port.

[0292] In some embodiments, the substance to be delivered may be a composition that includes components that include an aerosol-generating material and another aerosol-generating material that may or may not be heated. If desired, the composition and other aerosol-generating materials may include one or more active ingredients, one or more flavorings, one or more aerosol-forming materials, and / or one or more other functional materials.

[0293] stability The present invention enjoys the advantage of a longer shelf life than other tobacco extracts.

[0294] The nicotine content of the precursor and aerosol-forming materials after the freeze-drying process is calculated, indicating the amount of nicotine retained after processing. The nicotine recovery of the dried aerosol-forming material compared to the original tobacco extract is at least about 76% by weight on a dry weight basis. The nicotine recovery of the dried aerosol-forming material compared to the original tobacco extract may be at least about 60%, at least about 70%, at least about 75%, at least about 80%, or at least about 90% by weight on a dry weight basis.

[0295] The glycerol content of the precursor and dry aerosol generating material after the freeze-drying process is calculated to indicate the amount of glycerol retained after processing. The glycerol recovery of the dry aerosol generating material compared to the precursor material is at least about 85%. The glycerol recovery of the dry aerosol generating material compared to the precursor material can be at least about 70%, at least about 75%, at least about 80%, at least about 85%, at least about 90% or at least about 95% on a dry weight basis.

[0296] Example 1 In a first test, the precursor material consisted essentially of an aqueous tobacco extract and glycerol. The aqueous tobacco extract was further diluted with glycerol to about 24% by weight (calculated on a dry weight basis). The aqueous burley tobacco extract had a tobacco solids content of about 40% by weight and a moisture content of about 60% by weight. The precursor material was dried by freeze drying.

[0297] Example 2 In further tests, the precursor material consisted essentially of aqueous tobacco extract, glycerol and dextran 70. The glycerol content was from about 0 to about 15% v / v, or up to about 36% by weight, calculated on a dry weight basis. The precursor material was dried by lyophilization.

[0298] Example 3 The freeze-dried material of Example 1 or Example 2 is milled to obtain a loose powder with an average size of about 0.1 mm to about 1 mm. 200 mg of the powder is granulated and then compressed into tablets using a rotary tablet press with a force of 10 kN.

[0299] Example 4 The freeze-dried material of Example 1 or Example 2 is milled to obtain a loose powder with an average size of about 0.1 mm to about 1 mm. The powder is then extruded to form beads each containing 40 to 60 mg of freeze-dried material.

[0300] Example 5 The freeze-dried material of Example 1 or Example 2 is pulverized to obtain a loose powder with an average size of about 0.1 mm to about 1 mm. 100 mg of the powder is granulated and then formed into tablets with the addition of 5 mg of alginate as a binder.

[0301] 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, functions, features, structures, and / or other aspects described herein should not be considered as limitations on the scope of the invention as defined by the claims or limitations on the equivalents of the claims, and it is understood that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the present invention may suitably comprise, 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 that are not currently claimed but may be claimed in the future.

Claims

1. A component comprising an aerosol-generating material containing a dried precursor material containing an extract derived from a fragrance-containing and / or active plant material.

2. Approximately 50m ２ The component according to claim 1, having a BET surface area of ​​less than or equal to / g.

3. The component according to claim 1 or 2, wherein the component is a compressed tablet.

4. The component according to claim 1 or 2, comprising a binder.

5. The component according to claim 4, wherein the binder is included in an amount of about 0.1% to about 30% by weight, based on the total weight of the tablet.

6. The component according to claim 4, wherein the binder is selected from the group consisting of starch, polysaccharides, pectin, cellulose, cellulose derivatives such as carboxymethylcellulose, and alginates.

7. A component according to claim 1 or 2, having a size of approximately 1 mm to approximately 20 mm.

8. The component according to claim 1 or 2, which essentially consists of a dry aerosol-generating material and an optional binder.

9. The component according to claim 1 or 2, wherein the aerosol generating material further comprises an aerosol forming material.

10. The component according to claim 1 or 2, wherein the precursor material comprises an extract derived from a plant material containing fragrance or active ingredients in an amount of about 10 to about 95% by weight.

11. The component according to claim 1 or 2, wherein the precursor material comprises about 1 to about 36% by weight of an aerosol-forming material.

12. The component according to claim 1 or 2, wherein the precursor material comprises 0 to about 40% by weight of an excipient.

13. The component according to claim 1 or 2, wherein the aerosol generating material comprises about 45 to about 99% by weight of a dried extract derived from the fragrance-containing or active plant material.

14. The component according to claim 1 or 2, wherein the aerosol generating material comprises about 1 to about 34% by weight of an aerosol-forming material.

15. The component according to claim 1 or 2, wherein the aerosol-generating material comprises about 0 to about 25% by weight of an excipient.

16. The component according to claim 1 or 2, wherein the plant material is selected from the group consisting of tobacco, eucalyptus, star anise, cocoa, and hemp.

17. The component according to claim 1 or 2, wherein the extract derived from the fragrance-containing or active plant material is an aqueous extract.

18. The component according to claim 1 or 2, wherein the extract derived from the fragrance-containing or active plant material is an aqueous tobacco extract.

19. The component according to claim 1 or 2, wherein the dry aerosol-generating material contains about 40 to about 99% by weight of tobacco solids.

20. The component according to claim 1 or 2, wherein the aerosol-generating material has a water content of approximately 5% or less (calculated on a wet weight basis).

21. The component according to claim 1 or 2, comprising a heating material embedded within the aggregate.

22. The component according to claim 21, wherein the heating material is heated by electrical resistance.

23. The component according to claim 21, wherein the heating material is a susceptor.

24. A component according to claim 1 or 2 for use in an aerosol supply system.

25. An article comprising one or more components as described in claim 1.

26. The article according to claim 25, comprising means for preventing or reducing the absorption of moisture by the dry aerosol-generating material.

27. The article according to claim 26, wherein the means is provided separately from the one or more aggregates.

28. The article according to claim 27, wherein the means includes a film or wrapper containing an impermeable coating or an adsorbent or desiccant material.

29. A non-combustible aerosol supply system comprising the components described in claim 1 or the article described in claim 25.

30. The non-combustion aerosol supply system according to claim 29, wherein the system is configured to heat the components to form steam and / or aerosols.

31. The non-combustible aerosol supply system according to claim 29, further comprising a further aerosol-generating material that is heated to form an aerosol and / or vapor, wherein the further aerosol-generating material is optionally a liquid.

32. The non-combustion aerosol supply system according to claim 31, wherein the components are heated by the aerosol and / or vapor generated from the further aerosol-generating material.

33. A non-combustion aerosol supply system according to claim 31, comprising means for heating the further aerosol-generating material to form vapor, but not comprising separate means for heating the components.

34. A method for providing a component comprising: drying a precursor material containing an extract derived from a fragrance-containing and / or active plant material to form an aerosol-generating material; and forming the aerosol-generating material into a component by compression.

35. The method according to claim 34, wherein the precursor material is dried by spray drying or freeze-drying.

36. The method according to claim 34 or 35, comprising adding a binder to particles of the aerosol-generating material before or during the formation of the aerosol-generating material into constituent elements.

37. The method according to claim 34 or 35, comprising adding an aerosol-forming material to particles of the aerosol-generating material before or during the formation of the aerosol-generating material into constituent elements.

38. The method according to claim 34 or 35, wherein the aerosol-generating material is compressed into components by extrusion molding.

39. A method for providing a component including an aerosol generating material, Freezing a precursor material containing fragrance-containing and / or active ingredient-derived extracts from plant materials, A method comprising drying the frozen precursor material to form the constituent material including the aerosol generating material.

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