Compositions Comprising Aerosol-Forming Materials and Binders and Uses Thereof - Patent application

Abstract

The present invention relates to a composition comprising an aerosol-forming material, comprising a dry precursor material comprising an extract from a fragrance and / or active-containing plant material and optionally an aerosol-forming material, and a binder. 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 and a substrate comprising the composition.

Description

[Technical field]

[0001] The present invention relates to compositions comprising an aerosol-forming material and a binder, methods of preparing the compositions and methods of manufacturing substrates comprising the compositions on a support, and uses of the compositions. [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 composition comprising an aerosol-forming material and a binder in a ratio of about 1:10 to about 2:1 by weight, the aerosol-forming material comprising a dried precursor material comprising a flavorant and / or an extract from an active-containing plant material.

[0004] In some embodiments, the binder is selected from the group consisting of thermoreversible gelling agents, starches, polysaccharides, polysaccharide derivatives, celluloses, cellulose derivatives, gums, protein materials, polyol matrix materials, waxes, wax esters, and other polymers.

[0005] In some embodiments, the composition has adhesive properties.

[0006] In some embodiments, the aerosol-forming material is suspended or at least partially dissolved in a binder.

[0007] In some embodiments, the aerosol-generating material comprises an aerosol-forming material.

[0008] In some embodiments, the precursor material comprises from about 10 to about 95% by weight of an extract derived from a flavor- or active-containing plant material.

[0009] In some embodiments, the precursor material comprises from about 1 to about 36% by weight of the aerosol-forming material.

[0010] In some embodiments, the precursor material comprises from 0 to about 40% by weight of excipients.

[0011] In some embodiments, the aerosol-forming material comprises from 45 to about 100% by weight of a dried extract derived from flavor or active-containing plant material.

[0012] In some embodiments, the aerosol-forming material comprises from about 1 to about 34% by weight of the aerosol-forming material.

[0013] In some embodiments, the plant material is selected from the group consisting of tobacco, eucalyptus, star anise, cocoa, and hemp.

[0014] In some embodiments, the extract from the flavor- or active-containing plant material is an aqueous extract.

[0015] In some embodiments, the extract from flavor- or active-containing plant material is an aqueous tobacco extract.

[0016] In some embodiments, the aerosol-forming material has a moisture content of about 5% or less (calculated on a wet weight basis).

[0017] In some embodiments, the composition further comprises an additional fragrance or active.

[0018] In some embodiments, the composition does not include added filler or diluent materials.

[0019] According to a second aspect of the present invention there is provided a substrate comprising a composition according to the first aspect on a support.

[0020] In some embodiments, the support comprises one or more selected from the group consisting of paper, card, cardboard, cardboard, recycled materials, plastic materials, ceramic materials, activated carbon, glass, sintered materials, composite materials, plant-derived materials, fabrics or fleeces, fibrous tow metals, and metal alloys.

[0021] In some embodiments, the composition covers at least a portion of a surface of a substrate.

[0022] In some embodiments, multiple discrete portions of the composition are provided on a substrate.

[0023] In some embodiments, the composition is allowed to dry or cure.

[0024] In some embodiments, the composition is used to adhere portions of substrates to one another.

[0025] In some embodiments, the support comprises a heating material.

[0026] According to a third aspect of the present invention there is provided an article comprising a composition according to the first aspect or a substrate according to the second aspect.

[0027] According to a fourth aspect of the present invention there is provided a non-combustion aerosol delivery system comprising a composition according to the first aspect or a substrate according to the second aspect.

[0028] According to a fifth aspect of the present invention there is provided a method of providing a composition according to the first aspect comprising drying a precursor material comprising an extract from a flavour and / or active-containing plant material to form an aerosol-forming material, and combining the aerosol-forming material with a binder.

[0029] In some embodiments, the method further comprises adjusting the particle size of the aerosol-forming material.

[0030] In some embodiments, the aerosol-forming material is suspended or at least partially dissolved in a binder.

[0031] According to a sixth aspect of the present invention there is provided a method of providing a substrate according to the second aspect comprising drying a precursor material comprising an extract from a flavour and / or active-containing plant material to form an aerosol-forming material, combining the aerosol-forming material with a binder and applying the composition to a support.

[0032] In some embodiments, the composition is dried or cured in contact with the substrate.

[0033] In some embodiments, the precursor material is dried by spray drying or freeze drying.

[0034] 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]

[0035] [Figure 1] 1 is a schematic diagram of a substrate comprising a composition described herein. [Diagram 2] FIG. 2 is a schematic diagram of another substrate comprising a composition described herein. [Diagram 3] 1 is a side cross-sectional view of a first embodiment of a consumable including a substrate as described herein. [Figure 4] FIG. 4 is a perspective view of a non-combustion aerosol delivery device for generating aerosol from the consumable composition shown in FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0036] 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.

[0037] 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.

[0038] 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.

[0039] The present invention relates to compositions comprising dried or dehydrated aerosol-forming materials formed from extracts from flavorants and / or active-containing plant materials. In some embodiments, the extracts are liquid solutions or suspensions and may be dried or dehydrated using processes such as spray drying or freeze drying. The dried or dehydrated aerosol-forming materials may be formed from precursor materials comprising extracts from flavorants and / or active-containing plant materials and aerosol-forming materials.

[0040] Aerosol-generating materials that include dried extracts from fragrance- and / or active-containing plant materials contain high concentrations of fragrance and / or active substances, with little or no material that does not contribute to the aerosol generated from the dry aerosol-generating material. Thus, a small amount of aerosol-generating material is 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.

[0041] 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.

[0042] 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.

[0043] 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.

[0044] Unless otherwise stated, references to water content herein are references to water content as measured by Karl Fischer titration.

[0045] 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.

[0046] 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.

[0047] Preventing or reducing the absorption of water by the aerosol-forming material also helps manage or avoid the phenomenon known as "hot puffs."

[0048] In the present disclosure, the aerosol-generating material is provided in a composition that includes a binder. The combination of the aerosol-generating material and the binder is referred to herein as a composition. The ratio of the aerosol-generating material to the binder is about 1:10 to about 2:1 by weight. Thus, there is sufficient binder to surround the aerosol-generating material, thereby protecting it from moisture in the environment.

[0049] The composition may be used in an aerosol delivery system to generate an aerosol. The composition may be applied to a substrate that provides the composition and aerosol-generating material therein in a manner suitable for use in an aerosol delivery system. This is a particularly useful method for providing the aerosol-generating material, which is highly concentrated and therefore requires very small amounts compared to conventional aerosol-generating materials.

[0050] Binder In the compositions described herein, the aerosol-forming material is combined or mixed with one or more binders. The compositions include a ratio of aerosol-forming material to one or more binders of about 1:10 to about 2:1 by weight.

[0051] In a preferred embodiment, the aerosol-forming material is dried before the aerosol-forming material is combined with a binder.

[0052] In some embodiments, the one or more binders are selected from the group consisting of thermoreversible gelling agents such as gelatin, starches, polysaccharides, polysaccharide derivatives, celluloses, cellulose derivatives, gums, protein materials, polyol matrix materials, waxes, wax esters, and other polymers.

[0053] 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.

[0054] In other embodiments, the one or more bonding agents are adhesives or pressure sensitive adhesives, such as a solvent based adhesive, a polymer dispersion adhesive, a pressure sensitive adhesive, a contact adhesive, a thermoplastic adhesive, or a hot melt adhesive.

[0055] In some embodiments, the adhesive is polyvinyl acetate (PVA).

[0056] In some embodiments, the binder does not contain water. This may be preferred because the aerosol-generating material is very sensitive to water and can easily absorb moisture and change from a solid to a paste in the presence of too much water. Furthermore, some support materials may also be sensitive to water. Some support materials, such as paper and card, can easily absorb moisture. As a result, such materials may weaken, deform, or discolor when in contact with an aqueous binder. Also, the presence of water may require a drying step to remove the water, which requires energy input.

[0057] In some embodiments, the binder comprises a non-aqueous solvent or is solvent-free. For example, the binder may comprise a solvent-free hot melt adhesive. Such a binder may be applied to a moisture-sensitive support material.

[0058] The physical and chemical properties of the binder are important: in addition to adhering the aerosol-forming material to the substrate, and in some embodiments forming a coating around the aerosol-forming material, the binder must also be stable and remain in place during the period between manufacture and use by the consumer.

[0059] In some embodiments, it is important that the binder is suitable for inclusion in a substrate or article for use in an aerosol generating system, and in particular that the binder can be heated to a maximum temperature of about 250° C. to about 350° C. without releasing compounds that are not suitable for inhalation by the user.

[0060] In some embodiments, it is desirable for the binder to become permeable when the aerosol-generating material is heated to generate an aerosol. This may be necessary to ensure that the aerosol can be released from the aerosol-generating material surrounded by the binder. In some embodiments, the binder is made permeable by at least some partial melting or other decomposition of the binder material.

[0061] In some embodiments, the decomposition of the binder involves the binder losing its physical integrity such that it no longer forms a barrier around the aerosol-forming material, which may involve, for example, the binder melting, disappearing, disintegrating, or otherwise breaking down.

[0062] It may be expected that when a binder material is heated to its melting point, its bonding properties may be compromised. Thus, the binder material should be selected to remain intact when exposed to normal environmental temperatures. Thus, in some embodiments, the binder material used must be stable at temperatures below 40 or 50° C. In some embodiments, it may be desirable to select a binder material that remains intact while exposed to more extreme temperatures that may be encountered during storage and transportation, such as temperatures of 60-80° C.

[0063] In some embodiments, the binder can become permeable as the temperature increases to about 100-110° C. to avoid overheating of moisture present in the coated aerosol-generating material. In some embodiments, the binder opens rapidly upon heating to form an aerosol. This reduces the likelihood that the binder will impede volatilization and the resulting release of gas or vapor.

[0064] In some embodiments, the temperature at which the binder becomes permeable, e.g., 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.

[0065] Additionally or alternatively, the temperature at which the binder becomes 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.

[0066] In some embodiments, the amount of binder in the composition is about 5% to about 95% by weight, or about 35% to about 95% by weight, based on the weight of the total composition. In some embodiments, the amount of binder is at least about 5% by weight, at least about 10% by weight, at least about 15% by weight, at least about 20% by weight, at least about 25% by weight, at least about 30% by weight, at least about 35% by weight, or at least about 40% by weight, based on the weight of the total composition. In some embodiments, the amount of binder is 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, based on the weight of the total composition.

[0067] In some embodiments, the binder provides adhesive properties to the composition. For example, in some embodiments, the composition includes a binder in an undried or uncured form. The composition may be in the form of a liquid, a slurry, a gel, or a semi-solid. The composition may be tacky or adhesive-like.

[0068] For example, in some embodiments, the composition includes a binder in a dried or cured form. The composition may be in the form of a solid, a dried coating, or a semi-solid. The dried or cured composition may be less tacky than the undried or uncured composition, or may be non-tacky. In some embodiments, the composition may bond to a surface or substrate with which it has come into contact when it has dried or cured.

[0069] In some embodiments, the composition is formed by adding the aerosol-generating material to an undried or uncured binder, which allows the materials to mix and causes the aerosol-generating material to be at least partially coated or surrounded by the binder, and once the binder is dried or coated, the aerosol-generating material becomes at least partially embedded in the composition.

[0070] In some embodiments, the aerosol-forming material is soluble or partially soluble in the binder or other components of the composition, such as the solvent, such that when the aerosol-forming material is incorporated into the composition, it dissolves or partially dissolves.

[0071] In some embodiments, the aerosol-forming material is not soluble in the binder or other components of the composition such that when the aerosol-forming material is incorporated into the composition, it does not dissolve and retains its solid form.

[0072] In some embodiments, the binder material comprises an additive that is released when the composition is heated, and thus contributes to the generated aerosol.For example, the binder may comprise an active agent, including one or more of the active agents described elsewhere herein.In addition or alternatively, the binder may comprise a flavoring, including one or more of the flavorings and flavorings described elsewhere herein.In some embodiments, the flavoring added to the binder is a hydrophobic flavoring.This may mean that the flavoring increases the hydrophobicity of the composition.

[0073] Dry aerosol-generating materials The aerosol-generating material comprises a dried extract from a flavoring and / or active-containing plant material. In some embodiments, the aerosol-generating material further comprises an aerosol-forming material.

[0074] In some embodiments, the aerosol-generating material is formed by drying a precursor material that includes a flavorant and / or an extract from an 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 flavorants.

[0075] In some embodiments, the extract from the perfume 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 be dried.

[0076] 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.

[0077] The precursor material and / or the dry aerosol forming material may also optionally include one or more other functional materials.

[0078] Thus, the aerosol-forming material may include one or more active agents and / or flavorings, and optionally one or more aerosol-forming materials. The precursor material and / or dry aerosol-forming material may also, optionally, include one or more other functional materials.

[0079] The present invention takes advantage of aerosol-forming materials that are formulated to have a long shelf life and can therefore 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-forming material 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.

[0080] In some embodiments, the hygroscopic aerosol-forming material has 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 alone (i.e., without the protection from moisture provided by the compositions described herein) 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 an aerosol-forming material is exposed to the environment (e.g., upon storage in an open container, etc.), the water content rapidly increases to greater than 20% or even 25% (calculated on a wet weight basis) as measured by gas chromatography-thermal conductivity detector (GC-TCD) or Karl Fischer titration.

[0081] Compositions including the dry aerosol-forming materials described herein are stable over a range of temperatures and humidities, providing long shelf lives and thus facilitating storage and transportation. 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%, 50% or even 90% relative humidity prior to use.

[0082] Aerosol-forming materials also have the advantage of having a high concentration of the desired components, meaning that a relatively small amount of the aerosol-forming 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.

[0083] 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.

[0084] In some embodiments, the extract from flavor- or active-containing plant material is an extract from tobacco material.

[0085] 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.

[0086] 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).

[0087] 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 flavoring 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 flavoring or active-containing plant material (calculated on a wet weight basis). In some embodiments, the precursor material comprises about 50% by weight of tobacco extract (calculated on a wet weight basis).

[0088] 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 flavor 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).

[0089] 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).

[0090] 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.

[0091] 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).

[0092] 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).

[0093] 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.

[0094] 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.

[0095] 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.

[0096] 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.

[0097] In some embodiments, the dry aerosol-generating material and / or the precursor material includes one or more actives, which may be obtained from an extract or may be added, in some embodiments, a flavoring or an extract from an active-containing plant material includes the actives.

[0098] 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.

[0099] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0100] In some embodiments, the precursor material may include extracts from other plant source(s) along with or in place of tobacco extract.

[0101] 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 tea or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, la bender, 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: peppermint, mentha cv, Egyptian mint, peppermint, cologne mint, candy mint, curly mint, Kentucky kernel mint, horse mint, pineapple mint, pennyroyal mint, green peppermint, and apple mint.

[0102] 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.

[0103] 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.

[0104] 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).

[0105] 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).

[0106] The aerosol-generating material and / or precursor material may include cannabidiol (CBD).

[0107] The aerosol generating and / or precursor materials may include nicotine and cannabidiol (CBD).

[0108] The aerosol-generating and / or precursor materials may include nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol).

[0109] The aerosol-generating material further comprises an aerosol-forming material, which in some embodiments is included in the precursor material.

[0110] 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.

[0111] 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.

[0112] 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.

[0113] 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.

[0114] Combinations of two or more aerosol forming agents may be used, in equal or differing proportions.

[0115] 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).

[0116] 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.

[0117] 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.

[0118] 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.

[0119] 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).

[0120] 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).

[0121] 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.

[0122] 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.

[0123] 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).

[0124] In some embodiments, the aerosol-forming 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 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.

[0125] 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).

[0126] 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.

[0127] 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.

[0128] 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.

[0129] 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.

[0130] 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.

[0131] 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.

[0132] [Table 1] The nicotine content in the formulation depends on the type of tobacco used and the presence of other components, namely aerosol formers and excipients.

[0133] 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.

[0134] 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, extract of botanical substance, synthetically derived material, 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, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, 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, ira Nile 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, damiane, 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), as well as 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.

[0135] 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.

[0136] 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.

[0137] 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.

[0138] 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.

[0139] 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.

[0140] 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.

[0141] 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.

[0142] 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.

[0143] 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.

[0144] 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.

[0145] 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.

[0146] 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.

[0147] 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.

[0148] 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.

[0149] 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).

[0150] In some embodiments, the aerosol-generating material is in the form of particles or granules. Smaller granular particles have a larger surface area to volume ratio and therefore may exhibit enhanced release of components compared to larger sized particles. They are also easier to combine with binders in the composition, providing uniform distribution of the aerosol-generating material throughout the composition. Smaller particles also provide a composition with a smoother consistency where the particles of the aerosol-generating material do not dissolve in other components of the composition.

[0151] Yet another advantage of using fine particles of aerosol-generating material in the composition is that it helps to ensure that the particles are surrounded by a binder and therefore protected from the environment.This means that this highly hygroscopic material is not exposed to moisture and therefore cannot absorb moisture.This means that no additional measures (such as coating or wrapping the aerosol-generating material) are required to protect the aerosol-generating material from moisture.

[0152] 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, about 0.4 mm or less, about 0.3 mm or less, about 0.2 mm or less, or desirably about 0.1 mm or less, as measured by sieving.

[0153] 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.

[0154] When preparing the dried precursor composition, the particle size of any solid material present can be reduced by grinding, shredding, cutting or crushing the tobacco 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.

[0155] 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.

[0156] 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.

[0157] 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.

[0158] 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.

[0159] 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.

[0160] 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.

[0161] In a small scale example, the precursor material is freeze-dried using a freeze-drying microscope, for example a Lyostat freeze-drying microscope.

[0162] 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.

[0163] 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.

[0164] 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.

[0165] 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.

[0166] 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.

[0167] 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.

[0168] Other components In some embodiments, the compositions described herein include one or more components in addition to the aerosol-forming material and a binder.

[0169] For example, the composition may include an aerosol-forming material in addition to the aerosol-forming material included in the aerosol-generating material. Such an aerosol-forming material may be any of the specific materials discussed elsewhere herein. In some embodiments, the additional aerosol-forming material may be included in an amount of at least about 5% by weight, at least about 10% by weight, at least about 15% by weight, at least about 20% by weight, at least about 25% by weight, or at least about 30% by weight of the total composition. Alternatively or additionally, the additional aerosol-forming material may be included in an amount of up to about 50% by weight, up to about 45% by weight, up to about 40% by weight, up to about 35% by weight, up to about 30% by weight, up to about 25% by weight, or up to about 20% by weight of the total composition.

[0170] In other embodiments, the composition may include a solvent. The solvent may be included to impart desired properties to the binder component, such as viscosity before drying or curing, or its ability to dissolve the aerosol-forming material. The solvent may be included in an amount of at least about 5%, at least about 10%, at least about 15%, at least about 20%, or at least about 30% by weight of the total composition. Alternatively or additionally, the solvent may be included in an amount of up to about 90%, up to about 80%, up to about 70%, up to about 60%, up to about 50%, or up to about 40% by weight of the total composition.

[0171] In some embodiments, the solvent is selected from the group consisting of water, alcohols such as ethanol and methanol, acetone, and carboxylic acid esters such as methyl acetate and ethyl acetate.

[0172] In other embodiments, the composition may include a filler, extender, or diluent. These ingredients may be included to impart desired properties to the composition before and / or after drying or curing. The filler, extender, or diluent may be included in an amount of at least about 1% by weight, at least about 5% by weight, at least about 10% by weight, at least about 20% by weight, or at least about 30% by weight of the total composition. Alternatively or additionally, the filler, extender, or diluent may be included in an amount of up to about 60% by weight, up to about 50% by weight, up to about 40% by weight, up to about 30% by weight, up to about 20% by weight, up to about 10% by weight, or up to about 5% by weight of the total composition.

[0173] 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 include one or more organic filler materials such as wood pulp, cellulose and cellulose derivatives. In certain cases, the composition does not include calcium carbonate such as chalk.

[0174] In some embodiments where the composition includes a filler component, the filler may be fibrous. For example, the filler may be a fibrous organic filler material, such as wood pulp, hemp fiber, cellulose or a cellulose derivative. Without wishing to be bound by any particular theory, it is believed that including a fibrous filler may increase the tensile strength of the composition.

[0175] In some embodiments, the composition may include a colorant. The addition of a colorant may change the visual appearance of the composition. By adding a colorant to the composition, the composition may match the color of other components of the substrate or article containing the composition. In some embodiments, the colorant may be included in an amount of at least about 1 wt.%, at least about 2 wt.%, or at least about 5 wt.% of the total composition. Alternatively or additionally, the colorant may be included in an amount of up to about 10 wt.%, up to about 7 wt.%, or up to about 5 wt.% of the total composition.

[0176] Natural or synthetic colorants may be used, such as natural or synthetic dyes, food grade colorants and pharmaceutical grade colorants.

[0177] The colorant may be incorporated during formation of the composition (e.g., when mixing ingredients including the binder and aerosol-forming material that form the composition) or may be applied to the composition after its formation (e.g., by spraying onto the surface of the composition).

[0178] In some embodiments, the composition may include a fragrance or active in addition to that included in the aerosol-forming material. The fragrance or active may be released from the composition together with the components of the aerosol-forming material upon heating. The fragrance or active may be any of those discussed elsewhere herein. In some embodiments, the additional fragrance or active may be included in an amount of at least about 1% by weight, at least about 2% by weight, or at least about 5% by weight of the total composition. Alternatively or additionally, the additional fragrance or active may be included in an amount of up to about 20% by weight, up to about 15% by weight, up to about 10% by weight, or up to about 5% by weight of the total composition.

[0179] In some embodiments, additional fragrances or actives may be included in the composition in encapsulated form.

[0180] In some embodiments, the composition can include a flame retardant additive to help ensure that the composition, or any substrate or article incorporated therein or thereon, will resist combustion when exposed to high temperatures or flame.

[0181] In some embodiments, the flame retardant additive is a salt. As used herein, a salt is a compound consisting of an ionic assembly of a cation and an anion. As used herein, a salt is one whose anion and / or whose cation may be effective in retarding combustion.

[0182] In some embodiments, the salt is a halide salt, i.e., has a halide anion. In some embodiments, the salt is a chloride salt or a bromide salt. The presence of high concentrations of chloride or bromide has been shown to retard combustion.

[0183] In some embodiments, the salt may be an alkali metal salt, i.e., has an alkali metal cation. In some embodiments, the salt has an alkaline earth metal cation. In some embodiments, the salt has a zinc cation or an iron cation, e.g., a ferric or ferrous cation. In some embodiments, the salt has an ammonium cation or a phosphonium cation.

[0184] In some embodiments, the salt has a carboxylate anion, for example, the salt may be an alkali metal carboxylate, such as potassium citrate, potassium succinate, potassium malate, potassium acetate, potassium tartrate, potassium oxalate, sodium citrate, sodium succinate, sodium acetate, or sodium malate.

[0185] In other embodiments, the salt has an anion selected from borate, carbonate, phosphate, sulfate, or sulfamate.

[0186] In some embodiments, sodium chloride (NaCl) is the flame retardant additive used. Wrappers with high chloride content have been shown to be difficult to burn. Additionally, sodium chloride is neutral, highly soluble, and does not affect the pH of the composition.

[0187] In some embodiments, the flame retardant additive is an alkaline earth metal oxide or hydroxide, hi some embodiments, the additive is magnesium oxide or magnesium hydroxide.

[0188] In some embodiments, the flame retardant additive may be included in an amount of at least about 3%, at least about 3.5%, at least about 4%, at least about 5%, at least about 6%, at least about 7%, at least about 8%, at least about 9%, or at least about 10% by weight of the total composition. Alternatively or additionally, the flame retardant additive is included in an amount of not more than about 50%, not more than about 40%, not more than about 30%, not more than about 25%, not more than about 20%, not more than about 15%, or not more than about 10% by weight of the total composition.

[0189] support The compositions disclosed herein can be provided on a support to provide a substrate. Due to the adhesive properties of some compositions, the support does not need to have a porous or rough surface to enhance adhesion of the composition to the support.

[0190] The support or layer of the support may be formed of any material suitable for receiving and retaining the aerosol-generating material. In some embodiments, the support provides a surface onto which the composition is applied. In some embodiments, the support may provide a sleeve or cover that surrounds and supports the composition.

[0191] The support may be or may comprise one or more materials selected from, for example, paper, card, cardboard, cardboard, recycled materials such as recycled paper or recycled plant materials, plastic materials such as polylactic acid, ceramic materials, activated carbon, glass, sintered glass, metals, sintered materials such as ceramics or plastics, composite materials, materials of plant origin, fabrics or fleeces, fibrous tows such as cellulose acetate tow, metals or metal alloys.

[0192] In some embodiments, the support comprises a material having an inherently rough surface. For example, the support or a portion thereof may be formed from a paper material, such as tipping paper, porous plug wrap, cigarette paper, or teabag paper. The paper may be a porous paper. In one example of a support surface comprising a paper material, the paper preferably has a weight of about 20 gsm to about 100 gsm.

[0193] In some embodiments, the support comprises a fabric, fleece or fibrous material, such as tow. Such support materials may inherently have a porous structure with spaces between the fibers.

[0194] In some embodiments, the substrate is a woven or nonwoven fabric or fleece comprising a plurality of fibers, hi some embodiments, the fleece or fabric is made by dry laid, air laid, wet laid, spun melt, melt blown, or the like processes to intertwine fibers or filaments into a web in a manner that does not involve weaving or knitting.

[0195] The fabric may include fibers formed from materials including cellulose fibers, viscose fibers, regenerated cellulose fibers, wood fibers, cotton fibers, wool fibers, or other fleece-forming polymers, such as polyglycolic acid fibers, polylactic acid fibers, polyhydroxyalkanoate fibers, polycaprolactone fibers, polybutylene succinate fibers, polybutylene succinate adipate fibers, and combinations thereof. In some embodiments, the fibers are heat stable and / or biodegradable.

[0196] In some embodiments, the support is a porous material such as an open cell reticulated foam or a sintered structure, hi some embodiments, the porous material comprises a ceramic material, an activated carbon material, a zeolite, silica, wood, cork, or other naturally occurring material with a porous surface.

[0197] In some embodiments, the substrate may be or include, for example, glass, a plastic material, a ceramic material, a composite material, a metal, or a metal alloy.

[0198] In Figure 1, there is shown a substrate 1 comprising a cylindrical support structure 2 the exterior surface of which is covered with a composition comprising an aerosol-forming material and a binder, as described herein. The adhesive properties of the composition mean that the composition can be applied to a surface and then dried or cured to provide a coating bonded to the surface.

[0199] In some embodiments, the substrate is a wrapper material, such as a paper wrapper. The composition may be applied to at least a portion of a surface of the wrapper. In some embodiments, the composition may be used as an adhesive to secure the wrapper in place or to hold the wrapper closed around a rod or aerosol-generating material.

[0200] 2 illustrates such an embodiment, showing a substrate 1 including a sheet wrapper 4 held in a rolled configuration by strips or stripes of an adhesive composition 3 as disclosed herein. In the embodiment shown, the wrapper 4 is wrapped around a section or plug of additional aerosol-forming material 5.

[0201] Such embodiments have the advantage that the aerosol-generating material can be inherently incorporated into the materials that are otherwise included in the substrate or article, minimizing additional manufacturing complexity and costs, and minimizing the material that needs to be heated in addition to the aerosol-generating material to generate the aerosol, and therefore minimizing the additional energy required.

[0202] In other embodiments, the substrate may be additional aerosol-forming material, such as tobacco material in the form of cut rag or reconstituted tobacco material. The composition may be added to the additional aerosol-forming material to introduce the dry aerosol-forming material contained in the composition. Additionally, the composition may be introduced to stabilize or structurally reinforce the additional aerosol-forming material.

[0203] In some embodiments, the support consists of or includes a heating material including one or more materials selected from the group consisting of conductive materials, magnetic materials, and magnetic conductive materials. 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, flat carbon steel, stainless steel, ferritic stainless steel, copper, and bronze.

[0204] 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.

[0205] In some embodiments, the composition is applied to the substrate at a plurality of spaced apart regions of the substrate's surface to form separate portions of aerosol-generating material embedded within a binder. Each of these portions can generate an aerosol for a single puff or sufficient aerosol for a series of puffs. In some embodiments, the substrate may allow portions of the aerosol-generating material to be heated independently. In other embodiments, the portions may be heated together, but the compositions may be formulated or provided in forms that generate different aerosols and / or generate aerosols at different times or at different rates.

[0206] Use of the composition Substrates including compositions comprising aerosol-forming materials and binders can be used in combustion or non-combustion aerosol delivery systems, or in aerosol-free delivery systems.

[0207] The present invention also relates to a consumable or article comprising an aerosol-forming material and a binder in a ratio of about 1:10 to about 2:1 by weight, wherein the aerosol-forming material comprises a dried precursor material comprising a fragrance and / or an extract derived from an active-containing botanical material.

[0208] In some embodiments, the substrate is provided in a consumable product. Alternatively, the substrate may be used as a consumable product.

[0209] A consumable is an article that includes an aerosol-forming material, where some or all of the aerosol-forming material is intended to be consumed during use by a user, where the aerosol-forming material, or at least a portion of the aerosol-forming material, is provided as part of a substrate as disclosed herein, including a composition that includes an aerosol-forming material and a binder.

[0210] The consumable may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer 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. As discussed above, at least some of these components of the consumable may be components of the substrate described herein.

[0211] The consumable may be of any shape or size suitable for a smoking device. In some embodiments, the consumable is rod-shaped. In other embodiments, it may take the form of a flat strip, a rod, or a flexible sleeve.

[0212] In some embodiments, the substrate comprising the composition disclosed herein is provided in an aerosol-generating device, such as a tobacco heating product (THP) or a hybrid e-cigarette product. Suitably, the substrate can be directly heated without combustion to provide an inhalable aerosol. In some embodiments, heating the substrate first decomposes the coating, breaking the barrier formed around the aerosol-generating material. The aerosolized components of the aerosol-generating material, such as glycerol, nicotine, and / or tobacco flavorings, are then released.

[0213] In some embodiments, the substrate comprising the composition comprising the aerosol-forming material and the binder may be incorporated into a consumable product in the absence of other carriers or other materials that require heating.

[0214] 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.

[0215] 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.

[0216] 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.

[0217] In some embodiments, the composition itself protects the hygroscopic aerosol forming material from absorbing moisture from the environment, eliminating the need to store the consumable in low humidity conditions prior to use.

[0218] In embodiments in which the composition itself does not protect the hygroscopic aerosol-forming material from absorbing moisture from the environment, the consumable may suitably include a moisture-impermeable coating that surrounds but may be separate from the aerosol-forming material. For example, the moisture-impermeable coating may surround the composition (and thereby surround the aerosol-forming material within the composition). 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.

[0219] In some embodiments, the consumable may include a sorbent or desiccant material. As mentioned above, the sorbent or desiccant material may be provided in the composition. Alternatively, the sorbent or desiccant material may be provided separately in 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 in the consumable. In other embodiments, the sorbent may be incorporated in a separate section of the consumable relative to the aerosol-generating material. This may have the advantage of reducing the exposure of the sorbent to the 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.

[0220] In yet another embodiment, the sorbent or desiccant material 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.

[0221] Delivery System The delivery systems described herein can be combustion aerosol delivery systems, non-combustion aerosol delivery systems, or aerosol-free delivery systems. 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.

[0222] 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.

[0223] 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.

[0224] 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.

[0225] 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.

[0226] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0227] 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.

[0228] 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.

[0229] 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 provided on a support. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel, 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.

[0230] 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.

[0231] In some embodiments, the present disclosure relates to consumables that include a composition that includes an aerosol-forming material and a binder and that are configured for use with a non-combustion aerosol delivery device. These consumables may be referred to as articles throughout this disclosure.

[0232] 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 a substrate or heat transfer material proximate to the heat generating power source.

[0233] 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.

[0234] In some embodiments, a consumable for use with a non-combustion aerosol delivery device may include a substrate comprising a composition comprising an aerosol-forming material and a binder, an aerosol-forming material storage region, an aerosol-forming material transfer component, an aerosol generator, an aerosol-generating region, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0235] 3 is a side cross-sectional view of a consumable or article 10 for use in an aerosol delivery system. Article 10 comprises a mouthpiece segment 11 and an aerosol generation segment 12.

[0236] The aerosol-generation segment 12 is in the form of a cylindrical rod and includes a section or plug of aerosol-generating material 14, such as cut rag tobacco or reconstituted tobacco material. The tipping segment 11 in the illustrated embodiment includes a body of material 15, such as a fibrous plug or filamentary tow. Disposed between the aerosol-generation segment 12 and the tipping segment 11 is a cooling section 13 that includes a hollow tube 16 formed from a suitable material, such as cellulose acetate, paper, or a heat absorbing material.

[0237] The consumable 10 further comprises a wrapper 17, such as a paper wrapper, circumscribing the mouthpiece segment 11, the cooling section 13, and the aerosol-generation segment 12. The wrapper may include a strip of an adhesive composition that includes an aerosol-generating material and a binder to hold the wrapper in place, as shown in FIG.

[0238] 4 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 10 shown in FIG. 3 or described 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.

[0239] 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.

[0240] 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 4, 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."

[0241] 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.

[0242] 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.

[0243] In some embodiments, the substance to be delivered may be a substrate aerosol-generating material as described herein, and optionally another aerosol-generating material that may or may not be heated. If desired, the substrate 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.

[0244] stability The present invention enjoys the advantage of a longer shelf life than other tobacco extracts.

[0245] 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.

[0246] 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.

[0247] Furthermore, when surrounded by a moisture impermeable coating, the content of volatile ingredients such as nicotine and flavorings, as well as the content of aerosol-forming materials in the aerosol-forming material, is maintained until the composition is heated to generate an aerosol, even in the absence of packaging or other protection from exposure to moisture.

[0248] 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.

[0249] 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.

[0250] Example 3 The freeze-dried material of Example 1 or Example 2 is milled to obtain a loose powder with an average particle size of about 10 μm to about 50 μm. 32.4 mg of the powder is then added to 130.7 mg of diluted PVA binder. This mixture is then applied to the surface of a cardboard strip for insertion into a tobacco heating product device to heat the composition and provide an aerosol for inhalation by the user.

[0251] Example 4 Ten separate portions of a composition comprising 5 mg of the lyophilized aerosol-forming material of Example 1 or Example 2 and 10 mg of hot melt adhesive are deposited on a surface of a substrate comprising an aluminum section capable of being heated by magnetic hysteresis heating. The substrate and portions of the composition are then heated to form an aerosol which is inhaled by a consumer.

[0252] Example 5 The freeze-dried material of Example 1 or Example 2 is milled to obtain a loose powder having an average particle size of about 10 μm to about 50 μm. 50 mg of the powder is then added to 50 mg of PVA binder. This mixture is then applied to the edge of a paper wrapper that circumscribes a rod tobacco material forming a consumable for use in a tobacco heating product device, thus holding the wrapper in place.

[0253] 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. A composition comprising an aerosol-generating material containing a dried precursor material containing a fragrance and / or an extract derived from an active plant material, and a binder, in a ratio of about 1:10 to about 2:1 by weight.

2. The composition according to claim 1, wherein the binder is selected from the group consisting of a thermoreversible gelling agent, starch, polysaccharides, polysaccharide derivatives, celluloses, cellulose derivatives, gum, protein material, polyol matrix material, wax, wax ester, and other polymers.

3. The composition according to claim 1 or claim 2, wherein the composition has adhesive properties.

4. The composition according to claim 1 or 2, wherein the aerosol-generating material is suspended or at least partially dissolved in the binder.

5. The composition according to claim 1 or 2, wherein the aerosol generating material includes an aerosol forming material.

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

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

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

9. The composition according to claim 1 or 2, wherein the aerosol generating material comprises 45 to about 100% by weight of the fragrance or a dried extract derived from an active plant material.

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

11. The 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.

12. The composition according to claim 1 or 2, wherein the extract derived from the fragrance or active plant material is an aqueous extract.

13. The composition according to claim 1 or 2, wherein the extract derived from the fragrance or active plant material is aqueous tobacco extract.

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

15. The composition according to claim 1 or 2, further comprising additional fragrances or active substances.

16. The composition according to claim 1 or 2, wherein the composition does not contain added fillers or diluent materials.

17. A substrate comprising the composition described in claim 1, on a support.

18. The substrate according to claim 17, wherein the support comprises one or more selected from the group consisting of paper, cardboard, thick paper, recycled materials, plastic materials, ceramic materials, activated carbon, glass, sintered materials, composite materials, plant-derived materials, fabric or fleece, fibrous tow metal, or metal alloys.

19. The substrate according to claim 17 or 18, wherein the composition covers at least a portion of the surface of the support.

20. The substrate according to claim 17 or 18, wherein a plurality of individual portions of the composition are provided on the support.

21. The substrate according to claim 17 or 18, wherein the composition is dried or cured.

22. The substrate according to claim 17 or 18, wherein the composition is used to bond parts of the substrates together.

23. The substrate according to claim 17 or 18, wherein the support comprises a heating material.

24. An article comprising the composition according to claim 1 or 2 or the substrate according to claim 17 or 18.

25. A non-combustible aerosol supply system comprising the composition according to claim 1 or 2 or the substrate according to claim 17 or 18.

26. A step of forming an aerosol-generating material by drying a precursor material containing a fragrance and / or an extract derived from an active plant material, A method for providing the composition according to claim 1, comprising the step of combining the aerosol-generating material with a binder.

27. The method according to claim 26, further comprising the step of adjusting the particle size of the aerosol-generating material.

28. The method according to claim 26 or claim 27, wherein the aerosol generating material is suspended or at least partially dissolved in the binder.

29. A step of forming an aerosol-generating material by drying a precursor material containing a fragrance and / or an extract derived from an active plant material, The steps include combining the aerosol-generating material with a binder, The steps include applying the composition to a support, A method for providing the substrate according to claim 17, including the above.

30. The method according to claim 29, wherein the composition is dried or cured in contact with the support.

31. The method according to claim 26 or 29, wherein the precursor material is dried by spray drying or freeze-drying.

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