Aerosol-forming compositions and uses thereof

Abstract

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

Description

[Technical field]

[0001] The present invention relates to an aerosol-forming composition, a method for making a suspension and uses thereof. [Background technology]

[0002] Smoking articles, such as cigarettes and cigars, burn tobacco to produce tobacco smoke during use. An alternative to these types of articles are non-combustion aerosol delivery systems that release compounds without combustion to form an inhalable medium. Some such systems include a liquid that is vaporized by heating to produce an inhalable vapor or aerosol.

[0003] Liquid aerosol-forming materials for use in such products may contain a variety of different actives and / or flavorings. Factors such as the concentration of the active and / or flavoring ingredients in the aerosol-forming material and the stability of the aerosol-forming material affect the characteristics of the aerosol generated. Summary of the Invention

[0004] According to a first aspect of the present invention there is provided an aerosol-forming composition comprising a solid aerosol-forming material comprising a dried extract of an extract from perfume-containing and / or active-containing plant material, the solid aerosol-forming material being suspended or dissolved in a liquid aerosol-forming material.

[0005] In some embodiments, the liquid aerosol generating material comprises one or more aerosol forming materials.

[0006] In some embodiments, the one or more aerosol forming materials are selected from the group consisting of 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.

[0007] In some embodiments, the aerosol generating composition contains from about 5 to about 35 mg of solid aerosol generating material per ml of aerosol generating composition.

[0008] In some embodiments, the aerosol generating composition contains from about 15 to about 25 mg of solid aerosol generating material per ml of aerosol generating composition.

[0009] In some embodiments, the solid aerosol-forming material is formed by drying a precursor composition that includes an extract from fragrance-containing and / or active-containing plant material.

[0010] In some embodiments, the precursor material is dried to a moisture content of about 0 to about 5% (calculated on a wet weight basis).

[0011] In some embodiments, the precursor material comprises from about 10 to about 100% by weight extract derived from flavor- or active-containing plant material.

[0012] In some embodiments, the precursor material comprises from about 1 to about 36% by weight of the aerosol-forming material.

[0013] In some embodiments, the precursor material comprises from 0 to about 40% by weight of excipients.

[0014] In some embodiments, the excipient is one or more selected from the group consisting of mannitol, sucrose, trehalose, lactose, sorbitol, raffinose, maltose, dextran 10, dextran 70, dextran 90, maltodextrin, gelatin, agar, cyclodextrin, PEG 2000-6000, (PVP10k).

[0015] In some embodiments, the precursor material comprises a liquid suspension comprising particles having an average particle size, as measured by sieving, of about 1 mm or less.

[0016] In some embodiments, the plant material is selected from the group consisting of tobacco, eucalyptus, star anise, cocoa, and hemp.

[0017] In some embodiments, the extract from the flavor-containing or active-containing plant material is an aqueous extract.

[0018] In some embodiments, the extract from flavor-containing or active-containing plant material is an aqueous tobacco extract.

[0019] In some embodiments, the solid aerosol-forming material comprises from about 40 to about 99% by weight tobacco solids.

[0020] In some embodiments, the solid aerosol-forming material is in the form of particles having a particle size, as measured by sieving, of up to about 1 mm.

[0021] In some embodiments, the aerosol generating composition is for use in an aerosol delivery system.

[0022] According to a second aspect of the present invention there is provided an article comprising a solid aerosol-forming material comprising a dried extract from perfume-containing and / or active-containing plant material, the solid aerosol-forming material being suspended or dissolved in a liquid aerosol-forming material.

[0023] In some embodiments, the article comprises an aerosol-forming composition according to the first aspect.

[0024] According to a third aspect of the present invention, there is provided a non-combustion aerosol delivery system comprising an aerosol generating composition according to the first aspect.

[0025] In some embodiments, the system is a vaping device or an electronic nicotine delivery system.

[0026] In some embodiments, the system is a hybrid delivery system that includes additional aerosol-forming materials.

[0027] According to a fourth aspect of the present invention, drying a precursor material comprising an extract from a fragrance-containing and / or active-containing plant material to form a solid aerosol-forming material; suspending or dissolving a solid aerosol forming material in a liquid aerosol forming material; A method is provided for providing an aerosol generating composition comprising:

[0028] In some embodiments, the precursor material is dried by spray drying or freeze drying.

[0029] In some embodiments, the methods include adjusting the particle size of the solid aerosol-forming material to a size of up to about 1 mm as measured by sieving.

[0030] In some embodiments, the method includes adjusting the particle size of any solid material in the precursor material to a size of up to about 1 mm as measured by sieving.

[0031] 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]

[0032] [Figure 1]FIG. 1 is a schematic cross-sectional view of a non-combustion aerosol delivery device for generating aerosols from the aerosol generating compositions described herein. [Diagram 2] FIG. 1 is a schematic cross-sectional view of a hybrid device for generating vapor or aerosol from an aerosol-forming composition described herein and an additional source of solid aerosol-forming material. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0033] Conventional liquid aerosol-generating materials used to generate vapor or aerosol in non-combustion aerosol delivery systems may contain flavorings and / or actives and aerosol-forming materials. For example, such liquids may contain glycerol and flavorings. In some instances, they further contain nicotine.

[0034] Such compositions are generally ineffective at replicating tobacco flavors.

[0035] 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.

[0036] 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.

[0037] The present invention relates to an aerosol-forming composition comprising a solid aerosol-forming material suspended or dissolved in a liquid aerosol-forming material, the solid aerosol-forming material comprising a dried extract from a flavor-containing and / or active-containing plant material.

[0038] In some embodiments, the extract from the flavor- and / or active-containing plant material is a liquid solution or suspension and may be dried or dehydrated using processes such as spray drying or freeze drying. The dried or dehydrated solid aerosol-generating material may be formed from a precursor material that includes an extract from the flavor- and / or active-containing plant material.

[0039] The present invention addresses some of the most important shortcomings of conventional vapor systems, namely, providing an aerosol that provides a real tobacco taste. Attempts have been made in the past to utilize liquid tobacco extracts in e-liquids for vapor systems. However, these extracts tend to be very diluted when added to other liquid components, and therefore cannot provide sufficient amounts of tobacco flavor. Stability of the liquid formulations can also be problematic as a result of the relatively high water content, which can cause instability and shorten the shelf life of the product. In contrast, the present invention provides tobacco or other plant extracts in a highly concentrated form that can provide a strong real tobacco taste to the inhalation experience. The taste experience is more authentic, since the aerosol-generating composition contains a wide range and complex blend of flavors derived from plants, as well as providing them in a concentrated form so that these flavors can be reliably perceived in the aerosol generated by the vapor system.

[0040] Aerosol-forming compositions that include dry extracts from flavor- and / or active-containing plant materials contain high concentrations of flavors and / or actives. Thus, small amounts of dry extract are sufficient to generate an aerosol having the desired active and flavor content. Furthermore, the dry extract produces an aerosol generated from the aerosol-forming composition that has desirable sensory properties.

[0041] 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.

[0042] 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.

[0043] Unless otherwise stated, references to water content herein are references to water content as measured by Karl Fischer.

[0044] The aerosol generating compositions may be used in non-combustion aerosol delivery systems.

[0045] 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.

[0046] Solid aerosol generating materials The solid aerosol-forming materials included in the aerosol-forming compositions of the present invention include dried extracts derived from flavor-containing and / or active-containing plant materials.

[0047] In some embodiments, the solid 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 the desired components of the precursor material, and thus the solid aerosol-generating material may include one or more actives and / or flavors.

[0048] 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.

[0049] The precursor material and / or the solid aerosol-forming material may also optionally include one or more other functional materials.

[0050] The present invention takes advantage of solid aerosol-forming 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 solid aerosol-forming materials reduces the evaporation of other solvents over time, reducing the decomposition of nicotine and / or other volatile compounds. The low moisture content also inhibits microbial growth.

[0051] For example, solid aerosol-forming materials and aerosol-forming compositions, including suspensions comprising dried extracts from fragrance-containing and / or active-containing plant materials as described herein, are stable over a range of temperatures and humidities, have long shelf lives, and are therefore easy to store 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 up to about 30%, or up to 50%, or even up to about 90% relative humidity prior to use.

[0052] Solid aerosol-forming materials also have the advantage of having a high concentration of the desired component, meaning that a relatively small amount of the solid aerosol-forming material is required and less energy is required to heat and release the desired component. Importantly, the aerosols generated from these materials also provide a reasonable intensity of authentic tobacco flavor.

[0053] In some embodiments, the extract from flavorant- or active-containing plant material is an extract from tobacco material.

[0054] 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 one or more of the following: reconstituted tobacco, leaf tobacco, extruded tobacco, and band-cast tobacco.

[0055] The precursor material that is dried to form the solid 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 of 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 of tobacco solids (calculated on a wet weight basis). In some embodiments, the precursor material comprises between about 20% and about 40% by weight of tobacco solids (calculated on a wet weight basis).

[0056] 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).

[0057] 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% 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 dry aerosol-forming material may comprise from about 60 to about 80% by weight of tobacco extract (calculated on a dry weight basis).

[0058] 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).

[0059] 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.

[0060] 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).

[0061] 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% by weight of tobacco solids (calculated on a dry weight basis). Additionally or alternatively, the solid 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 of tobacco solids. In some embodiments, the dry aerosol-forming material may comprise from about 60 to about 80% by weight of tobacco solids (calculated on a dry weight basis).

[0062] 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.

[0063] 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.

[0064] 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 about 0.3 mm or less, as measured by sieving or by observing the size of the particles by SEM. If necessary, the extract or precursor material can be processed to ensure that it does not contain particles having a size, as measured by sieving, larger than desired. In some embodiments, the extract or precursor material can be filtered or centrifuged to remove particles above a certain size. Alternatively or additionally, the extract or precursor material can be ground to reduce the size of any particles present.

[0065] 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.

[0066] In some embodiments, the solid aerosol-generating material and / or the precursor material includes one or more active substances, which may be obtained from an extract or may be added. In some embodiments, an extract from a flavored or active substance-containing plant material includes the active substances.

[0067] 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.

[0068] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0069] In some embodiments, the precursor material may include extracts from other plant source(s) along with or in place of tobacco extract.

[0070] 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.

[0071] 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.

[0072] 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.

[0073] In some embodiments, the solid aerosol-generating material 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 cannabiersoin (CBE), cannabicitran (CBT).

[0074] The solid 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).

[0075] The solid aerosol generating material and / or precursor material may include cannabidiol (CBD).

[0076] The solid aerosol generating and / or precursor materials may include nicotine and cannabidiol (CBD).

[0077] The solid aerosol generating and / or precursor materials may include nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol).

[0078] The solid aerosol-generating material further comprises an aerosol-forming material, which in some embodiments is included in the precursor material.

[0079] 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).

[0080] 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.

[0081] The amount of glycerol in the precursor material, and therefore the solid aerosol-generating material, is important as 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 lyophilization process and can lead to product collapse if the critical temperature of the formulation is exceeded.

[0082] 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.

[0083] In some embodiments, the solid 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).

[0084] In some embodiments, the solid aerosol forming material may comprise from about 1 to about 34% 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).

[0085] 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.

[0086] In some embodiments, the solid 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 stickiness of the material. The presence of an excipient may also affect the rate of (freeze) drying.

[0087] 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).

[0088] In some embodiments, the solid aerosol-generating material and / or precursor material includes one or more excipients in an amount of 0 to about 40% by weight on a wet weight basis, hi some embodiments, the precursor material can 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.

[0089] In some embodiments, the solid 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 solid 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).

[0090] In an exemplary embodiment, the solid aerosol-forming material includes, on a dry weight basis, about 36% glycerol, about 45% tobacco extract, and about 19% excipients.

[0091] In another exemplary embodiment, the solid 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.

[0092] 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.

[0093] 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.

[0094] 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.

[0095] 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.

[0096] [Table 1]

[0097] The nicotine content in the formulation depends on the type of tobacco used and the presence of other components, namely aerosol formers and excipients.

[0098] In some embodiments, the solid 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, starch, polysaccharides, pectin, cellulose, cellulose derivatives such as carboxymethylcellulose, and alginates.

[0099] In some embodiments, the solid aerosol-generating material and / or precursor material includes 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.

[0100] 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.

[0101] 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.

[0102] In some embodiments, the solid 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.

[0103] In some embodiments, the solid 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.

[0104] 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.

[0105] In some embodiments, the solid aerosol-forming material is in the form of a rod. 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.

[0106] 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.

[0107] 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.

[0108] 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.

[0109] The solid 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.

[0110] 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.

[0111] 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.

[0112] The inclusion of an acid can be beneficial in embodiments in which the solid 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 solid 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.

[0113] 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.

[0114] The solid aerosol-forming material may be in the form of particles, such as in the form of a powder, hi some embodiments, the solid aerosol-forming material is in the form of particles having a maximum particle size of about 1 mm, 900 μm, 800 μm, 700 μm, 600 μm, 500 μm, 400 μm, 300 μm, 200 μm, 100 μm, 90 μm, 80 μm, 70 μm, 60 μm, 50 μm, 40 μm, 30 μm, 20 μm, or a maximum particle size of 10 μm, as measured by sieving. In some embodiments, the solid aerosol-forming material is in the form of particles having a minimum particle size of about 5 μm, 10 μm, 15 μm, 20 μm, 25 μm, 30 μm, 35 μm, 40 μm, 45 μm, 50 μm, 60 μm, 70 μm, 80 μm, 90 μm, or a maximum particle size of 100 μm, as measured by sieving.

[0115] In some embodiments, the solid aerosol-forming material formed by freeze drying or spray drying is then processed as necessary by other suitable steps known to those of skill in the art to provide the dried material in the desired form, e.g., in the form of particles of a desired size(s).

[0116] In some embodiments, the lyophilized precursor material can be ground into particles and sieved to exclude particles that are deemed too small or too large for use as an aerosol generating material. 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 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 Microtrac CamSizer® X2 particle size and shape analyzer. The percentages referred to herein are volume percentages.

[0117] 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.

[0118] 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.

[0119] 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 solid aerosol-forming material. Because it may be desirable for the solid 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.

[0120] In a small scale example, the precursor material is freeze-dried using a freeze-drying microscope, for example a Lyostat freeze-drying microscope.

[0121] 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.

[0122] 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.

[0123] The solid aerosol-forming material has a lower water content than the precursor material. The water content of the solid 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.

[0124] 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.

[0125] 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.

[0126] 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.

[0127] Liquid aerosol generating materials The liquid aerosol-forming material may include one or more aerosol-forming materials capable of forming an aerosol. The aerosol-forming agent may be, for example, a polyol aerosol-forming agent or a non-polyol aerosol-forming agent. It may be a solid or liquid at room temperature, but is preferably a liquid at room temperature.

[0128] 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.

[0129] In some embodiments, the aerosol forming material 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.

[0130] 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.

[0131] Combinations of two or more aerosol forming agents may be used, in equal or differing proportions.

[0132] In some embodiments, the liquid aerosol generating material comprises or consists of one or more selected from glycerol, propylene glycol, and vegetable glycerol.

[0133] In some embodiments, the liquid aerosol-generating material may include additional ingredients, such as a flavoring. For example, in some embodiments, the liquid aerosol-generating material includes propylene glycol and a flavoring. The flavoring may be any one of the flavorings mentioned herein.

[0134] In some embodiments, the liquid aerosol generating material further comprises a solvent that facilitates dissolution of the dry aerosol generating material. For example, the liquid aerosol generating material may comprise a water component to dissolve the dry aerosol generating material. It may be desirable to keep the water content as low as possible, since the addition of water may adversely affect the stability and shelf life of the composition and also increases the amount of energy required to volatilize the liquid aerosol generating material. In some embodiments, the liquid aerosol generating material comprises up to about 5% v / v water, up to about 4%, up to about 3%, up to about 2.5%, up to about 2%, up to about 1.5%, or up to about 1% v / v water.

[0135] Aerosol-forming compositions The aerosol forming composition is formed by combining solid and liquid aerosol forming materials.

[0136] In some embodiments, the solid aerosol forming material is not soluble in the liquid aerosol forming material and the composition is a suspension.

[0137] In other embodiments, the solid aerosol forming material is at least partially soluble in the liquid aerosol forming material and the composition is a suspension or solution.

[0138] When the goal is to produce a solution, dissolution of the solid aerosol-forming material can be facilitated or accelerated by providing the solid aerosol-forming material in particulate form. For example, the particles may have an average particle size of about 100 μm or less, about 50 μm or less, about 25 μm or less, or about 10 μm or less, as measured by sieving.

[0139] In some embodiments, an aerosol-forming composition that is a suspension can be filtered or centrifuged to remove particles above a certain size.

[0140] To provide an aerosol-generating composition in the form of a solution, it may be possible to select a liquid aerosol-generating material having one or more components in which the solid aerosol-generating material is soluble. For example, as described above, the liquid aerosol-generating material may include a solvent.

[0141] Alternatively or additionally, to provide an aerosol-generating composition in the form of a solution, it may be possible to formulate the solid aerosol-generating material to exclude any components that are not soluble in the liquid aerosol-generating material. In some embodiments, the solid aerosol-generating material does not include an excipient that is insoluble in the liquid aerosol-generating material. In some embodiments, the solid aerosol-generating material includes an excipient or other component that is readily soluble in the liquid aerosol-generating material of the aerosol-generating composition.

[0142] To provide an aerosol generating composition in the form of a solution, it may be possible to formulate the solid aerosol generating materials to exclude any components that are not soluble in the liquid aerosol generating material.

[0143] Delivery System The delivery systems described herein can be non-combustion aerosol delivery systems.

[0144] As used herein, the term "delivery system" is intended to encompass systems that deliver at least one substance to a user, including combustion-based aerosol delivery systems, such as cigarettes for pipes, roll-up or reel-up cigarettes, cigars, and tobacco (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes, or other impactable materials); non-combustion-based aerosol delivery systems that release compounds from an aerosol-generating material without combusting the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems that generate an aerosol using a combination of aerosol-generating materials; and aerosol-free delivery systems that deliver 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 including inhalable powders, and oral tobacco including snuff or moist snuff, where the at least one substance may or may not include nicotine.

[0145] 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.

[0146] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0147] 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.

[0148] 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.

[0149] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates an aerosol using a combination of aerosol-generating materials, where one or more of the aerosol-generating materials may be heated. Each of the aerosol-generating materials may be, for example, in solid, liquid or gel form and may or may not contain nicotine. In some embodiments, the hybrid system 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.

[0150] The present invention also relates to consumables or articles comprising a solid aerosol-forming material, including a dried extract from a flavorant- and / or active-containing plant material suspended or dissolved in a liquid aerosol-forming material.

[0151] 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.

[0152] In some embodiments, the present disclosure relates to consumables that include 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.

[0153] 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 carbon substrate that can be energized to deliver power in the form of heat to an aerosol generating material or a heat transfer material proximate to the heat generating power source.

[0154] 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.

[0155] In some embodiments, consumables for use with non-combustion aerosol delivery devices may include an aerosol generating material, an aerosol generating material storage region, an aerosol generating material transfer component, an aerosol generator, an aerosol generating region, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0156] 1 shows a schematic cross-sectional view of one example of a vaping or vaporization device for heating the aerosol-generating compositions disclosed herein. Apparatus 11 has a heating chamber 14 that contains a reservoir 13 containing the aerosol-generating composition that is heated and vaporized in use.

[0157] The device 11 of FIG. 2 further includes an electronics / power chamber 16 that may contain, for example, an electrical control circuit and / or a power source (not shown). The electrical control circuit may include a controller, such as a microprocessor arrangement, configured and designed to control the heating of the smokable material via a heating element (not shown). The electrical control circuit may receive a signal, for example, from a puff-activated sensor that is sensitive to changes in pressure or changes in airflow rate that occur, in use, for example, upon initiation of a user's draw on the device 11. The electrical control circuit may then operate to cause heating of the aerosol generating composition "on demand". Various configurations for puff-activated sensors are available, including, for example, thermistors, electromechanical devices, mechanical devices, optical devices, opto-mechanical devices, and microelectromechanical systems (MEMS)-based sensors. Alternatively, the device may have a manually operable switch for the user to initiate a puff.

[0158] The heating chamber 14 is contained within the housing 12. Supports and / or insulating means (not shown) may be positioned between the heating chamber 14 and the housing 12, for example to help insulate the housing 12 from the heating chamber 14, so that the housing 12 does not get hot, or at least too hot to touch, during use.

[0159] Housing 12 includes an inlet 15 through which air is drawn into the device. Housing 12 also includes an outlet 17 at a mouthpiece 18 of device 11. Air is drawn into device 11 through inlet 15 and travels through the device, picking up aerosol emitted by the aerosol generating composition. The resulting aerosol generated by device 11 exits device 11 through outlet 19 and is inhaled by the user.

[0160] In other 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 an aerosol-generating composition disclosed herein that includes solid and liquid aerosol-generating materials as a solution or suspension. The additional aerosol-generating material(s) may be, for example, in the form of a solid, liquid, or gel, and may or may not contain nicotine. In some embodiments, the solid aerosol-generating material may include, for example, tobacco or a non-tobacco product.

[0161] In some embodiments, the aerosol generating composition, which is a solution or suspension, is heated to generate a vapor and / or aerosol. The concentrated flavors and / or actives provided by the solid aerosol generating material add flavors and / or actives, such as authentic tobacco taste and nicotine delivery, to the vapor and / or aerosol.

[0162] The vapor and / or aerosol generated from the aerosol-forming composition, which is a solution or suspension, may come into contact with the additional aerosol-forming material, thereby heating the additional aerosol-forming material and volatilizing its components. In other embodiments, the additional aerosol-forming material is heated by a separate heating means.

[0163] In other embodiments, vapor and / or aerosol generation from the two aerosol-generating materials in a hybrid system are generated separately and combined within the device or at an exit from the device.

[0164] 3 shows a schematic cross-sectional view of one example of a hybrid product for an aerosol-forming composition that is a solution or suspension and an additional solid aerosol-forming material. The device 21 has a housing 22 that houses a chamber 24 that houses a container containing a solid aerosol-forming material 23 that is heated and vaporized during use. The housing 22 also contains a liquid reservoir 25 that contains an aerosol-forming composition 26 that is a solution or suspension as disclosed herein, which is heated to form a vapor.

[0165] The device 21 further includes an electronics / power chamber 27 that may contain, for example, electrical control circuitry and / or a power source (not shown). The electrical control circuitry may include a controller, such as a microprocessor arrangement, constructed and arranged to control the heating of the container 23 and / or its contents, and the liquid 26 via one or more heating elements (not shown). The electrical control circuitry may enable the device 21 to be puff-activated to cause heating "on demand". Alternatively, the device 22 may have a manually operable switch for a user to initiate a puff.

[0166] The housing 22 also includes an inlet 28 through which air is drawn into the device. The housing 22 also includes an outlet 29 at the mouthpiece 30 of the device 21. Air is drawn into the device 21 through the inlet 28 and travels through the device picking up vapor generated by heating the liquid 26 in the liquid reservoir 25, as well as flavorings and / or active ingredients released by the container 23, and the resulting aerosol generated by the device 21 exits the device 21 through the outlet 29 and is inhaled by the user.

[0167] The hybrid device 21 shown diagrammatically in Figure 2 represents just one possible configuration of such an apparatus. The relative positions of the liquid reservoir 25 and the chamber 24 for holding the solid aerosol-generating material 23 can be varied, as can the path of the air flowing through the apparatus.

[0168] In one embodiment, the liquid reservoir is located upstream of the solid aerosol-generating material that is volatilized. Alternatively, the liquid reservoir may be located downstream of the solid aerosol-generating material that is volatilized. In yet another arrangement, two aerosol sources in the device can be located side-by-side, etc.

[0169] stability The present invention enjoys the advantage of a longer shelf life than other tobacco extracts.

[0170] The nicotine content of the precursor and solid 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.

[0171] 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.

[0172] 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.

[0173] 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.

[0174] Example 3 The freeze-dried material of Example 1 or Example 2 is milled to obtain a loose powder having an average size of about 10 μm to about 50 μm. 50 mg of the powder is then added to 800 mg of a liquid component comprising 50% by volume vegetable glycerol and 50% by volume propylene glycol. This aerosol generating composition is used in a vapor device that provides at least 150 puffs.

[0175] Example 4 The freeze-dried material of Example 1 or Example 2 is milled to obtain a loose powder having an average size of about 10 μm to about 50 μm. 20 mg of the powder is then added to 1 ml of a liquid component containing 60% by volume propylene glycol, 35% by volume vegetable glycerol, and 5% by volume water. This aerosol generating composition forms a particulate-free solution and is used in a vapor device that provides at least 200 puffs.

[0176] 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. In addition, the present disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. An aerosol-generating composition comprising a solid aerosol-generating material containing a dried extract derived from a fragrance-containing and / or active plant material, wherein the solid aerosol-generating material is suspended or dissolved in a liquid aerosol-generating material.

2. The aerosol generating composition according to claim 1, wherein the liquid aerosol generating material comprises one or more aerosol-forming materials.

3. The aerosol-generating composition according to claim 2, wherein the one or more aerosol-forming materials are selected from the group consisting of 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 mixture, benzyl benzoate, benzyl phenylacetate, tributyline, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

4. The aerosol generating composition according to claim 1 or 2, comprising about 5 to about 35 mg of solid aerosol generating material per 1 ml of the aerosol generating composition.

5. The aerosol generating composition according to claim 4, comprising about 15 to about 25 mg of solid aerosol generating material per 1 ml of the aerosol generating composition.

6. The aerosol-generating composition according to claim 1 or 2, wherein the solid aerosol-generating material is formed by drying a precursor composition containing an extract derived from a fragrance-containing and / or active plant material.

7. The aerosol-generating composition according to claim 6, wherein the precursor material is dried to a water content of about 0 to about 5% (calculated on a wet weight basis).

8. The aerosol-generating composition according to claim 6, wherein the precursor material comprises about 10 to 100% by weight of an extract derived from a fragrance-containing or active plant material.

9. The aerosol-generating composition according to claim 6, wherein the precursor material comprises about 1 to about 36% by weight of an aerosol-forming material.

10. The aerosol-generating composition according to claim 6, wherein the precursor material comprises 0 to about 40% by weight of an excipient.

11. The aerosol-generating composition according to claim 10, wherein the excipient is one or more selected from the group consisting of mannitol, sucrose, trehalose, lactose, sorbitol, raffinose, maltose, dextran 10, dextran 70, dextran 90, maltodextrin, gelatin, agar, cyclodextrin, PEG 2000-6000, (PVP 10k).

12. The aerosol-generating composition according to claim 6, wherein the precursor material comprises a liquid suspension containing particles having an average particle size of about 1 mm or less as measured by sieving.

13. The aerosol-generating composition according to claim 1 or 2, wherein the plant material is selected from the group consisting of tobacco, eucalyptus, star anise, cocoa, and hemp.

14. The aerosol-generating composition according to claim 1 or 2, wherein the extract derived from the fragrance-containing or active plant material is an aqueous extract.

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

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

17. The aerosol-generating composition according to claim 1 or 2, wherein the solid aerosol-generating material is in the form of particles having a particle diameter of approximately 1 mm at most, as measured by sieving.

18. An aerosol generating composition according to claim 1 or 2 for use in an aerosol supply system.

19. An article comprising a solid aerosol-generating material containing a dried extract derived from a fragrance-containing and / or active plant material, wherein the solid aerosol-generating material is suspended or dissolved in a liquid aerosol-generating material.

20. The article according to claim 19, comprising the aerosol-generating composition according to claim 1 or 2.

21. A non-combustion aerosol supply system comprising the aerosol generating composition according to claim 1 or 2.

22. The non-combustion aerosol supply system according to claim 21, wherein the system is a vaping device or an electronic nicotine delivery system.

23. The non-combustion aerosol supply system according to claim 21, wherein the system is a hybrid delivery system comprising further aerosol-generating materials.

24. A precursor material containing an extract derived from a fragrance-containing and / or active plant material is dried to form a solid aerosol-generating material, The solid aerosol generating material is suspended or dissolved in the liquid aerosol generating material, A method for providing an aerosol-generating composition containing [a specific compound / element].

25. The method according to claim 24, wherein the precursor material is dried by spray drying or freeze-drying.

26. The method according to claim 24 or 25, further comprising adjusting the particle size of the solid aerosol generating material, as measured by sieving, to a maximum size of approximately 1 mm.

27. The method according to claim 24 or 25, further comprising adjusting the particle size of any solid material in the precursor material to a maximum size of approximately 1 mm when measured by sieving.

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