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

Abstract

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

Description

Field

[0001] The present invention relates to compositions comprising an aerosol-forming material and a moisture impermeable coating, methods of making the compositions, and uses thereof.

[0002] Aerosol-generating materials for use in combustion or non-combustion aerosol delivery systems can include a variety of different actives and / or flavorants. Factors such as the concentration of volatile active and / or flavor ingredients in the aerosol-generating material, as well as the stability of the aerosol-generating material, affect the characteristics of the aerosol generated.

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

[0004] In some embodiments, the moisture impermeable coating decomposes when heated, allowing the release of volatile components generated by heating the aerosol-forming material.

[0005] In some embodiments, the moisture impermeable coating decomposes at a temperature of about 100° C. or greater.

[0006] In some embodiments, the moisture impermeable coating comprises one or more selected from the group consisting of polysaccharide or cellulosic materials or derivatives thereof; gums; protein materials; polyol matrix materials; waxes; wax esters; and polymers.

[0007] In some embodiments, the moisture impermeable coating completely encapsulates the aerosol-forming material.

[0008] In some embodiments, the moisture impermeable coating prevents or retards the absorption of moisture from the surrounding environment by the aerosol-forming material.

[0009] In some embodiments, the moisture impermeable coating has a thickness of about 1 μm to about 100 μm.

[0010] In some embodiments, the aerosol-forming material is in the form of granules.

[0011] In some embodiments, the granules have a particle size of about 1 mm to about 4 mm.

[0012] In some embodiments, the aerosol-forming material is in the form of an agglomerate or tablet formed from particles.

[0013] In some embodiments, the agglomerates or tablets have a size of about 3 mm to about 20 mm.

[0014] In some embodiments, discrete particles, agglomerates, or tablets of aerosol-forming material are surrounded by a moisture impermeable coating.

[0015] In some embodiments, different discrete particles, agglomerates, or tablet coatings of aerosol-forming material decompose at different temperatures or at different rates to control the release of volatile components produced by heating the dry aerosol-forming material.

[0016] In some embodiments, different discrete particles or portions of the aerosol-forming material are surrounded by coatings of different thicknesses.

[0017] In some embodiments, different discrete particles or portions of the aerosol-forming material are surrounded by coatings of different coating materials.

[0018] In some embodiments, the aerosol-generating material comprises an aerosol-forming material.

[0019] In some embodiments, the precursor material comprises from about 10 to about 95% by weight extract derived from flavor- or active-containing plant material.

[0020] In some embodiments, the precursor material comprises from about 1 to about 36 wt % of the aerosol-forming material.

[0021] In some embodiments, the precursor material comprises from 0 to about 40% by weight of excipients.

[0022] In some embodiments, the aerosol-forming material comprises from about 45% to about 99% by weight of a dry extract derived from flavor-containing or active-containing plant material.

[0023] In some embodiments, the aerosol-forming material comprises from about 1 to about 34% by weight of the aerosol-forming material.

[0024] In some embodiments, the aerosol-forming material comprises from 0 to about 25% by weight of an excipient.

[0025] In some embodiments, the plant material is selected from the group consisting of tobacco, eucalyptus, star anise, cocoa, and hemp.

[0026] In some embodiments, the extract from the perfume-containing or active-containing plant material is an aqueous extract.

[0027] In some embodiments, the extract from flavor-containing or active-containing plant material is an aqueous tobacco extract.

[0028] In some embodiments, the aerosol-forming material comprises from about 40 to about 99% tobacco solids by weight.

[0029] In some embodiments, the aerosol-forming material has a moisture content of about 5% or less (calculated on a wet weight basis).

[0030] In some embodiments, the composition is for use in an aerosol delivery system.

[0031] According to a second aspect of the present invention, there is provided an article comprising an aerosol-forming material comprising a dry precursor material comprising an extract from perfume-containing and / or active-containing plant material, and a moisture impermeable coating surrounding the aerosol-forming material.

[0032] In some embodiments, the article comprises a film or wrapper comprising a moisture impermeable coating, hi some embodiments, the moisture impermeable coating is deposited on a moisture permeable carrier.

[0033] In some embodiments, an article comprises a composition according to the first aspect.

[0034] According to a third aspect of the invention there is provided a non-combustion aerosol delivery system comprising a composition according to the first aspect or an article according to the second aspect.

[0035] According to a fourth aspect, there is provided a method of providing a composition comprising drying a precursor material comprising an extract from a fragrance-containing and / or active-containing plant material to form an aerosol-forming material, and applying a moisture impermeable coating surrounding the aerosol-forming material.

[0036] In some embodiments, the precursor material is dried by spray drying or freeze drying.

[0037] In some embodiments, the moisture impermeable coating is applied by a fluidized bed coating process.

[0038] In some embodiments, the moisture impermeable coating is formed as part of the spray drying or freeze drying step.

[0039] In some embodiments, the moisture impermeable coating-forming material is included in the precursor material.

[0040] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0041] [Figure 1] 1 is a side cross-sectional view of a first embodiment of a consumable comprising a composition as described herein. [Diagram 2] FIG. 2 is a perspective view of a non-combustion aerosol delivery device for generating aerosol from the consumable composition shown in FIG. 1. Detailed Description

[0042] An aerosol-forming material is a material that is capable of generating an aerosol when energized, for example, by heating, irradiation, or in any other manner.

[0043] Conventional aerosol generating materials, including tobacco materials or tobacco extracts, may be used in combustion and non-combustion aerosol generating devices, including hybrid devices and tobacco heating products, to provide users with an aerosol having an 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. In addition, the moisture content of the aerosol generating material increases with moisture absorption, negatively impacting the release of substances such as nicotine and flavors. Aerosol generating materials generated using conventional methods and procedures generally need to be used within 1-3 days of generation. Thus, a need exists for improving the shelf life of aerosol generating materials.

[0044] A further problem associated with conventional aerosol-forming materials that include tobacco materials or tobacco extracts is that the concentrations of desired components, such as nicotine and flavors, are relatively low. This limits the concentration of these desired components in the aerosol that is generated. In addition, 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 and release the desired components.

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

[0046] Aerosol-forming materials that include dried extracts from fragrance-containing and / or active-containing plant materials contain high concentrations of fragrance and / or actives and little or no material that does not contribute to the aerosol generated from the dry aerosol-forming material. Thus, small amounts of aerosol-forming material are sufficient to generate an aerosol with the desired active and fragrance content. Furthermore, the aerosol can be generated with a relatively low level of energy input.

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

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

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

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

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

[0052] Conventional aerosol-generating materials do not always need to be protected from moisture in the surrounding environment. This is because conventional aerosol-generating materials are not hygroscopic, and are not particularly moisture sensitive. In addition, humectants such as glycerol are often included in conventional aerosol-generating materials in appropriate amounts to target a certain 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 materials and the quality of the aerosols generated. Moreover, water absorption can occur to such an extent that the dry powder becomes a paste-like consistency, which is undesirable in the compositions and consumables described herein.

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

[0054] In the present disclosure, a moisture impermeable coating is provided surrounding an aerosol-forming material, the coating being intended to prevent or reduce exposure of the aerosol-forming material to moisture, and thus prevent or reduce absorption of moisture by the aerosol-forming material prior to its use.

[0055] Thus, there is provided a composition comprising an aerosol-forming material, the aerosol-forming material including a dry precursor material comprising an extract from a fragrance-containing and / or active-containing plant material, and a moisture impermeable coating surrounding the aerosol-forming material.

[0056] 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 and / or when the aerosol-forming material is surrounded by a moisture-impermeable coating, but also after incorporation into an aerosol product and subsequent transportation and storage. This stable water content is observed even though hygroscopic aerosol-forming materials are believed to rapidly absorb moisture when exposed to the environment, even under "normal" humidity conditions. Indeed, when an aerosol-forming material is described as hygroscopic, this means that the aerosol-forming material rapidly absorbs water from the surrounding environment, causing its water content to increase significantly. For example, upon exposure of the uncoated aerosol-forming material to the environment (e.g., upon storage in an open container, etc.), the moisture content rapidly increases to greater than 20% or greater than 25% (calculated on a wet weight basis) as measured by gas chromatography-thermal conductivity detection (GC-TCD) or Karl Fischer titration.

[0057] Moisture-impermeable coating In the compositions disclosed herein, the dry aerosol-forming material is surrounded by a moisture impermeable coating, which creates a moisture impermeable barrier around the dry aerosol-forming material.

[0058] The physical and chemical properties of the coating material are important. In addition to forming a moisture-impermeable coating, the coating must also be stable and remain in place during the period from manufacture to use by the consumer. In some embodiments, it is desirable for the moisture-impermeable coating to become permeable when the aerosol-generating material is heated to generate the aerosol. This is necessary to ensure that the aerosol can be released. In some embodiments, the coating becomes permeable by melting or other decomposition of the coating material or at least a portion of the coating.

[0059] In some embodiments, degradation of the coating involves the coating losing its physical integrity such that it no longer forms a barrier around the aerosol-forming material, which may include, for example, the coating melting, crumbling, disintegrating, or otherwise breaking down.

[0060] It can be expected that the integrity of the moisture-impermeable coating may be compromised when the coating material is heated to its melting point. Thus, the coating material should be selected such that the moisture-impermeable coating remains intact when exposed to normal environmental temperatures. Thus, in some embodiments, the coating material used should be one that forms a stable moisture-impermeable coating at temperatures below 40 or 50° C. In some embodiments, it may be desirable to select a coating material that forms a moisture-impermeable coating that remains intact at more extreme temperatures, such as those of 60-80° C. that may be encountered during storage and transportation.

[0061] In some embodiments, the moisture impermeable coating may become permeable when the temperature is raised to about 100-110° C., thus avoiding overheating of any moisture present in the coated aerosol-generating material. In some embodiments, the coating opens rapidly upon heating to form an aerosol. This reduces the possibility that the coating will interfere with the volatilization and release of the resulting gas or vapor.

[0062] In some embodiments, the temperature at which the moisture impermeable coating becomes permeable, for example as a result of decomposition, is at least about 50°C, at least about 60°C, at least about 70°C, at least about 80°C, at least about 90°C, at least about 100°C, at least about 110°C, at least about 120°C, at least about 130°C, at least about 140°C, at least about 150°C, at least about 160°C, at least about 170°C, at least about 180°C, at least about 190°C, or at least about 200°C.

[0063] Additionally or alternatively, the temperature at which the moisture impermeable coating 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 about 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.

[0064] In some embodiments, the moisture impermeable coating comprises one or more materials selected from polysaccharide or cellulosic materials or derivatives thereof; gums; protein materials; polyol matrix materials; waxes; wax esters; and polymers. 100 nm to about 50 μm. In some embodiments, the average particle size of the coating powder is at least about 100 nm, at least about 200 nm, at least about 300 nm, at least about 400 nm, at least about 500 nm, at least about 600 nm, at least about 700 nm, at least about 800 nm, at least about 900 nm, at least about 1 μm, at least about 2 μm, at least about 3 μm, at least about 4 μm, at least about 5 μm, at least about 10 μm, at least about 15 μm, at least about 20 μm, at least about 25 μm, at least about 30 μm, at least about 35 μm, or at least about 40 μm.

[0065] Additionally or alternatively, the average particle size of the coating powder is about 50 μm or less, about 45 μm or less, about 40 μm or less, about 35 μm or less, about 30 μm or less, about 25 μm or less, about 20 μm or less, about 15 μm or less, about 10 μm or less, about 5 μm or less, about 4 μm or less, about 3 μm or less, about 2 μm or less, or about 1 μm or less.

[0066] In some embodiments, the coating adheres to the surface of the aerosol-generating material by inter-particle forces, such as van der Waals forces. In some embodiments, the surface of the aerosol-generating material is sticky so that particles of the coating material adhere easily to the surface to form a complete or substantially complete coating. The stickiness of the aerosol-generating material can be adjusted by adjusting the water content of the aerosol-generating material at the time the coating is applied.

[0067] In some embodiments, the moisture impermeable coating is formed as part of the spray drying or freeze drying step. For example, a moisture impermeable coating-forming material may be included in the precursor material and form a coating as the precursor material is dried. This may require that the aerosol-forming material and the coating material have chemical properties that ensure that the coating material migrates to the surface of the dried material to surround the dried aerosol-forming material. For example, in some embodiments, the coating material is a non-polar and / or hydrophobic material that may be included in the precursor material to be dried.

[0068] As discussed above, the moisture-impermeable coating has the benefit of protecting the aerosol-generating material from moisture, as well as the negative effects this may have on the material and the aerosol it generates when heated. The coating can also control the release of the aerosol generated by heating the aerosol-generating material, as mentioned. In addition, other benefits are provided by the coatings described herein. The aerosol-generating material can be sticky or tacky. This can make the material difficult to process and handle. A coating applied to the surface of the aerosol-generating material masks this stickiness, making the composition easier to process and handle. The coating can also enhance the structural integrity of the aerosol-generating material. The coating provides additional support and strength to the particles or portions of the aerosol-generating material, reducing its tendency to break down and form dust, which can be detrimental to the product and the equipment used to make the product.

[0069] Dry aerosol-generating materials The aerosol-generating material comprises a dried extract from a flavor-containing and / or active-containing plant material. In some embodiments, the aerosol-generating material further comprises an aerosol-forming material.

[0070] In some embodiments, the aerosol-generating material is formed by drying a precursor material that includes an extract from a fragrance-containing and / or active-containing plant material. The drying process is selected to preserve the desired components of the precursor material, and thus the aerosol-generating material may include one or more actives and / or fragrances.

[0071] 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.

[0072] The precursor material and / or the dry aerosol forming material may also optionally include one or more other functional materials.

[0073] 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.

[0074] The present invention takes advantage of aerosol-forming materials that are formulated to increase shelf life, and therefore can be easily transported and stored. Without wishing to be bound by any particular theory, it is hypothesized that the low moisture content of the dry aerosol-forming materials reduces the evaporation of other solvents over time, reducing the degradation of nicotine and / or other volatile compounds. The low moisture content also inhibits microbial growth.

[0075] Compositions including the dry aerosol-forming materials described herein are stable over a range of temperatures and humidities, have an increased shelf life, and are therefore easy to store and transport. In some embodiments, the compositions may be stored at temperatures ranging from 0 to 35° C. In some embodiments, the compositions may be stored at up to about 50% relative humidity, and optionally as high as 90% RH, prior to use.

[0076] 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 to heat and release the desired components, and less energy is needed. Importantly, the aerosols generated from these materials also provide a moderate intensity of authentic tobacco taste.

[0077] 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 wide range of products without the need for further processing.

[0078] In some embodiments, the extract from the perfume- or active-containing plant material is an extract derived by contacting the plant material with a suitable solvent, such as an aqueous solvent, or an alcohol, such as ethanol. The liquid portion, including the solvent and any dissolved plant components, may then be separated or partially separated from the remaining solid plant material to provide the extract, which is included in the precursor composition and dried.

[0079] In some embodiments, the extract derived from flavorant- or active-containing plant material is an extract derived from tobacco material.

[0080] The tobacco extract or material may be derived from or may be any type of tobacco and any part of the tobacco plant, including tobacco lamina, stems, petioles, veins, scraps and shorts, 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 a blend of tobacco materials optionally including those listed herein. The tobacco may be expanded, e.g., dry ice expanded tobacco (DIET), or processed in any other manner. In some embodiments, the tobacco material may be reconstituted tobacco material. The tobacco may be pre-processed or unprocessed, e.g., solid stem (SS); shredded dried stem (SDS); steam-treated stem (STS); or any combination thereof. The tobacco material may be fermented, cured, uncured, toasted, or otherwise pre-processed. The tobacco material may be provided in the form of cut rag tobacco. Cut rag tobacco may, for example, have a cut width of at least 15 cuts per inch (approximately 5.9 cuts per cm, equivalent to a cut width of approximately 1.7 mm). Cut rag tobacco may be formed from a mixture of forms of tobacco material, such as a mixture of one or more of reconstituted tobacco, leaf tobacco, extruded tobacco, and band cast tobacco.

[0081] The precursor material that is dried to form the aerosol-forming material may comprise at least about 10 wt%, at least about 15 wt%, at least about 20 wt%, at least about 25 wt%, at least about 30 wt%, at least about 35 wt%, or at least about 40 wt% tobacco solids (calculated on a wet weight basis). Additionally or alternatively, the precursor material may comprise up to about 60 wt%, up to about 55 wt%, up to about 50 wt%, up to about 45 wt%, or up to about 40 wt% tobacco solids (calculated on a wet weight basis). In some embodiments, the precursor material comprises between about 20 wt% and about 40 wt% tobacco solids (calculated on a wet weight basis).

[0082] In some embodiments, the precursor material comprises at least about 10 wt%, about 20 wt%, at least about 30 wt%, at least about 40 wt%, at least about 50 wt%, at least about 60 wt%, at least about 70 wt%, at least about 80 wt%, or at least about 90 wt% of an extract derived from tobacco or other flavor-containing or active substance-containing plant material (calculated on a wet weight basis). Alternatively or in addition, the precursor material may comprise up to about 99 wt%, up to about 90 wt%, up to about 80 wt%, up to about 70 wt%, or up to about 60 wt% of an extract derived from tobacco or other flavor-containing or active substance-containing plant material (calculated on a wet weight basis). In some embodiments, the precursor material comprises approximately 50 wt% of tobacco extract (calculated on a wet weight basis).

[0083] In some embodiments, the aerosol-forming material may comprise at least about 45 wt%, at least about 50 wt%, at least about 60 wt%, at least about 70 wt%, at least about 80 wt%, at least about 90 wt%, or at least about 95 wt% tobacco material or tobacco extract, or flavorant- or active-containing plant material extract (calculated on a dry weight basis). In some embodiments, the aerosol-forming material may comprise from about 60 to about 80 wt% tobacco extract (calculated on a dry weight basis).

[0084] In some embodiments, the dry aerosol forming material may contain from about 2 wt% to about 10 wt% nicotine, or from about 3 to about 6 wt% nicotine (calculated on a dry weight basis).

[0085] In some embodiments, the precursor material comprises approximately 50% v / v tobacco extract. When the precursor material comprises approximately 50% v / v tobacco extract, the tobacco extract has a tobacco solids content of between about 55 and about 60% v / v, and the total tobacco solids content of the precursor material is between about 27.5 and about 30% v / v.

[0086] In some embodiments, the tobacco extract has a solids content (calculated on a wet weight basis) of between about 40 and about 65 wt%, between about 45 and about 65 wt%, or between about 40 and about 60 wt%. In some embodiments, the moisture content of the tobacco extract is between about 35 wt% and about 65 wt%, or between about 35 and about 55 wt% (calculated on a wet weight basis). In some embodiments, the nicotine content of the tobacco extract is between about 1 wt% and about 5 wt% (calculated on a wet weight basis).

[0087] In some embodiments, the dry aerosol-forming material may comprise at least about 45 wt%, at least about 50 wt%, at least about 60 wt%, at least about 70 wt%, at least about 80 wt%, at least about 90 wt%, or at least about 95 wt% tobacco solids (calculated on a dry weight basis). Additionally or alternatively, the aerosol-forming material may comprise up to about 99 wt%, up to about 98 wt%, up to about 95 wt%, up to about 90 wt%, or up to about 80 wt% tobacco solids (calculated on a dry weight basis). In some embodiments, the dry aerosol-forming material may comprise between about 60 and about 80 wt% tobacco solids (calculated on a dry weight basis).

[0088] In some embodiments, the tobacco extract is an aqueous tobacco extract. In some embodiments, the tobacco extract is concentrated and subsequently diluted before being added to the precursor material and dried. In other embodiments, the tobacco extract is not concentrated and may be used directly in the precursor material.

[0089] The precursor material may be in the form of a slurry, suspension, gel, liquid or solid, although in some embodiments, which may be preferred, the precursor material is in the form of a suspension or liquid. In some embodiments, particles of solid material may be removed from the extract and / or from the precursor material by filtration and / or centrifugation.

[0090] 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.

[0091] The water content of the precursor material may be at least about 20 wt%, at least about 30 wt%, at least about 40 wt%, at least about 50 wt%, at least about 60 wt%, at least about 70 wt%, at least about 80 wt%, or at least about 90 wt% on a wet weight basis. Alternatively or in addition, the water content of the precursor material may be up to about 95 wt%, up to about 90 wt%, up to about 85 wt%, up to about 80 wt%, up to about 75 wt%, up to about 70 wt%, up to about 65 wt%, up to about 60 wt%, up to about 55 wt%, or up to about 50 wt% on a wet weight basis. In some embodiments, the water content of the precursor material is between about 40 and about 50 wt% (50% to 60 v / v%) on a wet weight basis. If the precursor material has a lower water content, the spray / freeze drying process will be faster since there is less water to be removed.

[0092] In some embodiments, the dry aerosol-forming material and / or the precursor material includes one or more actives, which may be derived from an extract or may be added. In some embodiments, an extract from a perfume-containing or active-containing plant material includes the actives.

[0093] The active substance may be a bioactive 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.

[0094] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0095] In some embodiments, the precursor material may include extracts from other botanical source(s) in addition to or in place of tobacco extract.

[0096] As described herein, an extract may comprise or be derived from one or more botanical substances, or components, derivatives or extracts thereof. As used herein, the term "botanical substances" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, skins, etc. An extract may comprise or be derived from botanical substances in the form of liquids, gases, solids, powders, dusts, ground particles, granules, pellets, chips, strips, sheets, etc. Examples of botanical substances are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, laurel, liquorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea, e.g. green tea or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemongrass, lemon juice, lemon juice powder, lemon juice syrup ... Montpelier, mint, juniper, elderflower, vanilla, wintergreen, shiso, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiane, marjoram, olive, lemon balm, lemon basil, chives, Calvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.The mint may be selected from the following mint varieties: Mentha arventis, Grapefruit mint (Mentha cv), Egyptian mint (Mentha niliaca), Peppermint (Mentha piperita), Cologne mint (Mentha piperita citrata cv), Chocolate mint (Mentha piperita cv), Curly mint (Mentha spicata crispa), Wild mint (Mentha cardifolia), Horse mint (Mentha longifolia), Pineapple mint (Mentha suaveolens variegata), Pennyroyal mint (Mentha pulegium), English spearmint (Mentha spicata cv), and Apple mint (Mentha suaveolens).

[0097] In some embodiments, the extract comprises or is derived from one or more botanical substances or components, derivatives or extracts thereof selected from eucalyptus, star anise, cocoa and hemp.

[0098] In some embodiments, the extract comprises or is derived from one or more botanical substances selected from rooibos and fennel, or components, derivatives or extracts thereof.

[0099] In some embodiments, the aerosol-generating material and / or precursor material comprises one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiol acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabichromene (CBC), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), and cannabielsoin (CBE), cannabicitran (CBT).

[0100] The aerosol-generating and / or precursor materials may comprise one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD) and THC (tetrahydrocannabinol).

[0101] The aerosol-generating material and / or precursor material may include cannabidiol (CBD).

[0102] The aerosol generating and / or precursor materials may include nicotine and cannabidiol (CBD).

[0103] The aerosol-generating and / or precursor materials may include nicotine, cannabidiol (CBD) and THC (tetrahydrocannabinol).

[0104] The aerosol-generating material further comprises an aerosol-forming material, hi some embodiments, the aerosol-forming material is included in the precursor material.

[0105] 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-forming agent or a non-polyol aerosol-forming agent. It may be a solid or liquid at room temperature, but is preferably a liquid at room temperature.

[0106] 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, meso-erythritol, 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.

[0107] 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.

[0108] In some embodiments, the aerosol-forming material comprises, consists essentially of, or consists of glycerol. Glycerol provides a visible aerosol when an aerosol generating device is used. Generally, consumers prefer aerosol-generating devices that provide a visible aerosol because they allow consumers to visualize the product and what they are consuming. This makes glycerol a desirable choice as an aerosol-forming material. Propylene glycol has the advantage of being a better flavor carrier than glycerol.

[0109] A combination of two or more aerosol forming agents of similar or different properties may be used.

[0110] In some embodiments, the precursor material comprises at least about 1 wt%, at least about 5 wt%, at least about 10 wt%, or at least about 20 wt% aerosol-forming material (calculated on a wet weight basis). Additionally or alternatively, the precursor material may comprise up to about 40 wt%, up to about 35, up to about 30 wt%, up to about 25 wt%, up to about 20 wt%, or up to about 10 wt% aerosol-forming material (calculated on a wet weight basis).

[0111] In embodiments of the invention where the aerosol-forming material is glycerol, the precursor material may contain up to 36 wt% glycerol. The inventors have demonstrated that dry weight content levels of aerosol-forming material up to 36 wt% (calculated on a dry weight basis) are possible.

[0112] 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. If the concentration of glycerol is too high, it can be detrimental to the critical temperature of the product during the freeze-drying process, and can lead to 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 suitable and pleasant aerosol to the consumer.

[0113] 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 cryoprotective properties. Nevertheless, the inventors have discovered that precursor materials including glycerol may be freeze-dried to form highly useful aerosol-generating materials.

[0114] In some embodiments, the dry aerosol-forming material may comprise at least about 1 wt%, at least about 5 wt%, at least about 10 wt%, at least about 20 wt%, at least about 30 wt%, or at least about 40 wt% of the aerosol-forming material (calculated on a dry weight basis).

[0115] In some embodiments, the dry aerosol-forming material may comprise from about 1 to about 34 wt.%, or from about 17 to about 34 wt.%, of the aerosol-forming material (calculated on a dry weight basis). In some embodiments in which the aerosol-forming material is glycerol, the dry aerosol-forming material may comprise from about 13 to about 34 wt.%, of glycerol (calculated on a dry weight basis).

[0116] In embodiments where burley tobacco is used, the aerosol-forming material may include about 17 to about 36 wt% glycerol. The amount of glycerol in the aerosol material is important since it is both an aerosol-forming material and a plasticizer. If the concentration of glycerol is too high, it can be detrimental to the critical temperature of the product during the freeze-drying process and can 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 an adequate and pleasant aerosol to the consumer.

[0117] 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 an aerosol-forming material. The excipients may also act as bulking agents or filler materials. In some embodiments, the inclusion of an excipient may also improve the handling properties of the dried aerosol-generating material, helping to retain its granular form by helping to reduce the moisture uptake and resulting increase in stickiness of the material. The presence of an excipient may also have an effect on the rate of (freeze) drying.

[0118] Suitable excipients include mannitol, sucrose, trehalose, lactose, sorbitol, raffinose, maltose, dextran, e.g., dextran 10, dextran 70, dextran 90, maltodextrin, gelatin, agar, cyclodextrin, and polyethylene glycols, e.g., PEG 2000-6000, and polyvinylpyrrolidone (PVP 10).

[0119] In some embodiments, the aerosol-forming material and / or precursor material comprises one or more excipients in an amount of 0 to about 40 wt% on a wet weight basis. In some embodiments, the precursor material may comprise at least about 1 wt%, at least about 10 wt%, at least about 20 wt%, at least about 30 wt%, and / or up to about 40 wt%, up to about 30%, up to about 20 wt%, or up to about 10 wt% of an excipient on a wet weight basis.

[0120] In some embodiments, the aerosol-forming material may comprise at least about 0.1 wt%, at least about 10 wt%, at least about 20 wt%, or at least about 25 wt% of excipients (calculated on a dry weight basis). In some embodiments, the aerosol-forming material may comprise up to about 25 wt%, up to about 20 wt%, up to about 15 wt%, or up to about 10 wt% of excipients (calculated on a dry weight basis).

[0121] In an exemplary embodiment, the aerosol-forming material includes, on a dry weight basis, about 36 wt% glycerol, about 45 wt% tobacco extract, and about 19 wt% excipients.

[0122] In another exemplary embodiment, the aerosol-forming material comprises, on a dry weight basis, from about 17 to about 39 wt.% glycerol, from about 41 to about 76 wt.% tobacco extract, and from 0 to about 28 wt.% excipients.

[0123] In embodiments where the excipient is agar, the precursor material may contain 0 wt%, about 5 wt%, or about 10 wt% agar. The inventors have found that agar makes the precursor material more viscous, and that the freeze-drying process is easier when the precursor material contains a lower concentration of the agar excipient.

[0124] In some embodiments, the precursor material comprises about 50 wt% tobacco extract, 0 to about 36 wt% aerosol forming agent (e.g., 0 to about 15 v / v%), and 0 to about 40 wt% excipients (e.g., about 37.5 v / v%). The tobacco extract may comprise about 55 wt% tobacco solids, with the total tobacco solids content of the precursor material being about 27.5 wt%.

[0125] In some embodiments, the precursor material comprises about 50 wt% tobacco extract, up to about 36 wt% (e.g., about 15 v / v%) glycerol, and 0 to about 40 wt% (e.g., about 37.5 v / v%) excipients. The tobacco extract may comprise about 55 wt% tobacco solids, and the total tobacco solids content of the precursor material is about 27.5 wt%.

[0126] Some sample formulations of dry aerosol-forming materials formed from aqueous tobacco extracts are summarized in Table 1 below, with amounts shown on a dry weight basis. 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, such as Dextran 70. Again, this may be replaced or partially replaced with alternative excipients, such as those disclosed herein.

[0127] [Table 1]

[0128] The percentage content of nicotine in the formulation depends on the type of tobacco used and the presence of other ingredients, namely aerosol formers and excipients.

[0129] In some embodiments, the aerosol-forming materials and / or precursor materials include one or more binders. In some embodiments, the one or more binders are selected from the group consisting of thermoreversible gelling agents, such as gelatin, starch, polysaccharides, pectin, cellulose, cellulose derivatives, such as carboxymethylcellulose, and alginates.

[0130] 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 can be used to create a desired taste, odor, or other somatic sensation in products intended for adult consumers, where local regulations permit. 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, mint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus, Drambuie, bourbon, Scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, Khat, naswar, betel quid, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, pepper, ginger, coriander, coffee, hemp, mint oil from any species of Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba , hazel, hibiscus, laurel, yerba mate, orange peel, rose, tea, e.g. green tea or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, black currant, valerian, pimento, mace, damienne, marjoram, olive, lemon balm, lemon basil, chives, Calvi, verbena, tarragon, limonene, thymol,camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners. They may be imitation, synthetic, or natural ingredients, or blends thereof. They may be in any suitable form, e.g., liquids such as oils, solids such as powders, or gases.

[0131] 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.

[0132] In some embodiments, the flavoring may include sensory agents aimed at achieving somatic sensations that are usually chemically induced and perceived by stimulating the fifth cranial nerve (trigeminal nerve) in addition to or instead of the olfactory or gustatory nerves, and these 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, eucolyptol, WS-3.

[0133] 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.

[0134] 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 components. In some embodiments, the precursor material contains less than 60 wt% of filler on a wet weight basis, e.g., between 1 wt% and 60 wt%, or between 5 wt% and 50 wt%, or between 5 wt% and 30 wt%, or between 10 wt% and 20 wt%.

[0135] When present, the filler may comprise 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 comprise one or more organic filler materials, such as wood pulp, hemp fibers, cellulose and cellulose derivatives.

[0136] 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 may include one or more compounds selected from cellulosic gelling agents, non-cellulosic gelling agents, guar gum, acacia gum, and mixtures thereof.

[0137] 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.

[0138] In some embodiments, the gelling agent includes (or is) one or more of hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose (HPMC), carboxymethyl cellulose, guar gum, or acacia gum.

[0139] 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.

[0140] 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 monobasic acid, a dibasic acid, and a tribasic acid. In some such embodiments, the acid may include 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.

[0141] 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, hi some embodiments, the acid is selected from one of lactic acid, benzoic acid, and levulinic acid.

[0142] 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.

[0143] The inclusion of an acid can be beneficial in embodiments in which the aerosol-forming 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-forming 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.

[0144] In certain embodiments, the aerosol-forming materials include a gelling agent, including a cellulosic and / or non-cellulosic gelling agent, an active agent, and an acid.

[0145] The dry aerosol-generating material can be in any solid form. For example, the aerosol-generating material can be in the form of particles, granules, or powder. The aerosol-generating material can 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 further 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).

[0146] In some embodiments, the aerosol-generating material is in the form of granules. The granules may be of any size, cross-sectional shape, or mass. Aerosol-generating materials in the form of granules are advantageous due to their high surface area to volume ratio, which positively impacts the release of volatiles from the material. This form also facilitates the incorporation of the material into an aerosol delivery system.

[0147] In some embodiments, the aerosol-forming material is free-flowing and non-sticky, which aids in further processing and handling of the aerosol-forming material.

[0148] Smaller granule particles have a greater surface area to volume ratio and therefore they may exhibit enhanced release of tobacco constituents as compared to larger sized particles.

[0149] In some embodiments, it may be desirable for the 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.

[0150] 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.

[0151] When preparing the dried precursor composition, the particle size of any solid material present can be reduced by grinding, chopping, cutting or crushing the plant material. Suitable equipment for producing such plant particles includes, for example, choppers, 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 provide particles that can be easily prepared from a variety of different plant materials with the characteristics described herein and provide a source of plant components that are easily released.

[0152] 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 even as small as 1 μm. The size of the particles may be determined by sieving or by observing the particles by SEM.

[0153] 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.

[0154] 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 a test sample are smaller than that value), a particle size distribution D50 of about 30 to about 200 μm (meaning that 50% of the particles in a test sample are smaller than that value), and a particle size distribution D90 of about 500 to about 2500 μm (meaning that 90% of the particles in a test sample are smaller than that value). These values ​​are determined using a particle size analyzer, Microtrac CamSizer® X2. The percentages referred to herein are volume percentages.

[0155] 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.

[0156] 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.

[0157] Spray drying and freeze drying The drying method used to dry the precursor material may be any suitable drying process, including freeze-drying or spray-drying processes. The drying process used must be compatible with the precursor material and the desired make-up of 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.

[0158] In a small scale example, the precursor material is freeze-dried using a freeze-drying microscope, for example, a Lyostat freeze-drying microscope.

[0159] In the spray drying process, precursor material is atomized and rapidly dried using hot gas. The use of spray drying provides the present invention with several advantages: the dry particle size can be controlled and can be constant; tobacco or flavor extracts or materials are heat sensitive, but can still be spray dried at relatively high inlet temperatures; the residence time required in the spray drying device is short; and the loss of flavor / volatiles is minimal. This makes the process adaptable to reduce the loss of volatile compounds and maintain the desired flavor of aerosol-generating materials.

[0160] Freeze-drying, also known as lyophilisation or cryodesiccation, is a process in which precursor materials are frozen, the temperature reduced and water removed via sublimation under reduced pressure conditions. Without wishing to be bound by any particular theory, it is believed that the low processing temperatures and rapid water loss via sublimation avoid changes to the structure, appearance and characteristics of the aerosol-forming material. This process preserves the structure of the precursor materials and reduces the loss and decomposition of volatile flavour compounds.

[0161] 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 wt%, about 1 wt%, about 2%, about 5 wt%, about 10 wt%, or about 20 wt% (calculated on a wet weight basis). The water content of the dry aerosol-forming material may be reduced by at least about 50 wt%, about 60 wt%, about 70 wt%, about 80 wt%, about 90 wt%, about 95 wt%, about 98 wt%, or about 100 wt% from the precursor material. In some embodiments, the dry aerosol-forming material has a water content of less than about 5 wt%, less than about 4 wt%, less than about 3 wt%, less than about 2 wt%, or less than about 1 wt% (calculated on a wet weight basis) as measured by gas chromatography thermal conductivity detector (GC-TCD) or Karl Fischer measurement.

[0162] In an exemplary embodiment of the invention, the precursor material comprises Burley tobacco extract and a moisture content of 60 wt%. After the freeze-drying process described herein, the dry aerosol-forming material has a moisture content of 3 wt%.

[0163] A lower moisture content of the dry aerosol-generating material is associated with a longer shelf life and stability. However, a very low moisture content is associated with a brittle structure and smaller particle size, and processing may take longer. 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 increase in stability may not be achieved. The dry aerosol-generating material may also become sticky and not as easy to handle as a higher moisture content.

[0164] The inventors have found that when a precursor material includes an excipient, the precursor material may be better suited to being dried via 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 and makes it more suitable for spray drying.

[0165] Use of the composition The compositions including aerosol-forming materials and coatings may be used in combustion or non-combustion type aerosol delivery systems, or in aerosol-free delivery systems.

[0166] In some embodiments, the composition comprising the aerosol-forming material and the moisture impermeable coating may be provided on a carrier or support. The support may have any shape, size, or configuration. For example, the composition may be provided in or on a rod-shaped support, or on the surface of a flat consumable or support.

[0167] In some embodiments, the support may be an 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.

[0168] In some embodiments, the support consists of or comprises a heating material comprising 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 comprise a metal or metal alloy. In some embodiments, the heating material may comprise one or more materials selected from the group consisting of aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite, plain carbon steel, stainless steel, ferritic stainless steel, copper, and bronze.

[0169] In some embodiments, the heating material may be heated by induction heating, a process in which an object is heated by passing a changing magnetic field through a 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.

[0170] The aerosol-generating materials may be provided in the form of separate units or portions that can be heated individually and independently of one another and each capable of generating a single puff of aerosol, or a series of puffs that can be used in a single use session.

[0171] In other embodiments, the coated composition may be provided as one or more tablets, beads or granules, which may be provided, for example, in a cartridge, pod or pouch. Alternatively, the coated tablets or beads may be provided for direct insertion into a suitably configured chamber or receptacle of a device, for example an aerosol generating device.

[0172] The present invention also relates to a consumable or article comprising an aerosol-forming material, the aerosol-forming material including a dry precursor material that includes an extract from a fragrance-containing and / or active-containing plant material, and a moisture-impermeable coating that surrounds the aerosol-forming material.

[0173] In some embodiments, the compositions disclosed herein are provided in a consumable product.

[0174] A consumable is an article comprising an aerosol-forming material that is intended to be consumed in part or in whole during use by a user, where the aerosol-forming material, or at least a portion of the aerosol-forming material, is in the form of a composition disclosed herein that includes an aerosol-forming material and a moisture impermeable coating.

[0175] The consumable may comprise 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 comprise an aerosol generator, such as a heater that generates heat during use to generate an aerosol from the aerosol-generating material. The heater may comprise, for example, a combustible material, a material heatable by electrical conduction, or a susceptor. The consumable may be of any shape or size that is suitable for a smoking device. In a preferred embodiment of the invention, the consumable is in the shape of a rod.

[0176] In some embodiments, the moisture impermeable coating surrounds the aerosol-forming material but may be separate from the composition. For example, the moisture impermeable coating may surround the composition (thereby surrounding the aerosol-forming material within the composition). In some embodiments, the moisture impermeable coating may be provided as a film or wrapper that is optionally deposited on a moisture permeable carrier.

[0177] In some embodiments, the composition comprising the aerosol-generating material and the moisture-impermeable coating is provided in an aerosol-generating device, such as a tobacco heating product (THP) or a hybrid e-cigarette product. Advantageously, the composition may be used directly as a solid substrate, where the composition is heated directly without combustion to provide an inhalable aerosol. In some embodiments, heating the composition first causes the coating to decompose, breaking down the barrier it forms around the aerosol-generating material. The aerosolized components of the aerosol-generating material, such as glycerol, nicotine, and / or tobacco flavorings, are then released.

[0178] Because the composition itself and / or the moisture-impermeable coating protects moisture-sensitive aerosol-forming materials, the composition or consumable does not need to be stored in low humidity conditions prior to use.

[0179] In some embodiments, the composition including the aerosol-forming material and the moisture impermeable coating may be incorporated into the consumable in the absence of any carrier or other substrate material that needs to be heated.

[0180] However, in some embodiments, the composition may be applied to a fibrous paper material to provide reconstituted tobacco. This process is similar to existing processes for preparing reconstituted tobacco by applying tobacco extract to a fibrous paper material, and may be modified by replacing the tobacco extract with a composition comprising an aerosol-forming material and a moisture impermeable coating. This is advantageous because the aerosol-forming material can be incorporated into existing manufacturing processes, but with an improved shelf life as described herein.

[0181] "Reconstituted tobacco paper" refers to tobacco material formed by a process in which tobacco raw material is extruded with a solvent to obtain a residue containing soluble extract and fibrous material, and then the extract (usually after concentration, and optionally after further processing) is recombined with fibrous material from the residue (usually after purification of the fibrous material, and optionally with the addition of a portion of non-tobacco fiber) by depositing the extract onto the fibrous material. The recombination process is similar to that for papermaking.

[0182] The reconstituted tobaccos described herein may be prepared by methods known to those skilled in the art for preparing reconstituted tobaccos.

[0183] 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.

[0184] Alternatively or in addition, 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.

[0185] In some embodiments, the total mass of dry aerosol-generating material is sufficient to deliver an aerosol, e.g., up to about 10 puffs, 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.

[0186] Delivery System The delivery systems described herein can be combustion-based aerosol delivery systems, non-combustion-based aerosol delivery systems, or aerosol-free delivery systems.

[0187] As used herein, the term "delivery system" is intended to encompass a system that delivers at least one substance to a user, including the following: Combustion-type aerosol delivery systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or hand-rolled or handmade cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smoking materials); Non-combustion aerosol delivery systems that release compounds from an aerosol-generating material without combusting the aerosol-generating material, such as e-cigarettes, tobacco heating products, and hybrid systems that generate aerosols using a combination of aerosol-generating materials; and Aerosol-free delivery systems that deliver at least one substance (which may or may not contain nicotine) to a user orally, nasally, transdermally, or otherwise, without forming an aerosol, including, but not limited to, lozenges, gums, patches, articles comprising powders for inhalation, and oral products such as oral tobacco (including snus or moist snuff, in which at least one substance may or may not contain nicotine) Examples include:

[0188] According to this disclosure, a "combustion-type" aerosol delivery system is one in which the component 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.

[0189] In some embodiments, the delivery system is a combustion-type aerosol delivery system, such as a system selected from the group consisting of cigarettes, cigarillos, and cigars.

[0190] In some embodiments, the present disclosure relates to components for use in combustion-type 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.

[0191] According to this disclosure, a "non-combustion" aerosol delivery system is one in which the component aerosol-generating materials (or components thereof) of the aerosol delivery system are not combusted or burned during use to facilitate delivery of at least one substance to a user.

[0192] In some embodiments, the delivery system is a non-combustion aerosol delivery system, for example a powdered non-combustion aerosol delivery system.

[0193] In some embodiments, the non-combustion aerosol delivery system is an e-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.

[0194] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. An example of such a system is a tobacco heating system.

[0195] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates an aerosol using a combination of aerosol-generating materials, one or more of which may be heated and may be a composition including an aerosol-generating material and a moisture-impermeable coating. 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 comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may, for example, include tobacco or a non-tobacco product.

[0196] 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.

[0197] In some embodiments, the present disclosure relates to consumables configured for use with non-combustion aerosol delivery devices, the consumables comprising a composition including an aerosol-forming material and a moisture impermeable coating. These consumables may be referred to as articles throughout this disclosure.

[0198] In some embodiments, the non-combustion aerosol delivery system, e.g., the non-combustion aerosol delivery device, may include a power source and a controller. The power source may be, for example, an electrical power source or a heat generating power source. In some embodiments, the heat generating power source includes a carbon substrate that may be energized to distribute electrical power in the form of heat to a composition or heat transfer material that includes an aerosol generating material and a moisture impermeable coating in proximity to the heat generating power source.

[0199] In some embodiments, the non-combustion aerosol delivery system may include a consumable receiving area, an aerosol generator, an aerosol-generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0200] In some embodiments, a consumable for use with a non-combustion type aerosol delivery device may comprise a composition including an aerosol-forming material and a moisture impermeable coating, an aerosol-forming material storage region, an aerosol-forming material transport component, an aerosol generator, an aerosol-generating region, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0201] 1 is a side cross-sectional view of a consumable or article 1 for use in an aerosol delivery system. The article 1 comprises a mouthpiece segment 2 and an aerosol generation segment 3.

[0202] The aerosol-generating segment 3 is in the form of a cylindrical rod and comprises a composition comprising an aerosol-generating material and a moisture impermeable coating 4. The composition can be any of the compositions comprising an aerosol-generating material and a moisture impermeable coating discussed herein.

[0203] Although described above in the form of a rod, the aerosol-generating segment 3 may be provided in other forms, for example as a plug, pouch or packet of material within the article.

[0204] The mouthpiece segment 2 of the illustrated embodiment comprises a body of material 5, for example a fiber or filament tow.

[0205] The rod-shaped consumable 1 further comprises a wrapping 6 , for example a wrapping paper, surrounding the mouthpiece segment 2 and the aerosol-generation segment 3 .

[0206] 2 shows an example of a non-combustion aerosol delivery device 100 for generating an aerosol from an aerosol-generating medium / material, such as a composition of a consumable 110 as described herein. Broadly speaking, device 100 may be used to heat a replaceable article 110 comprising an aerosol-generating medium, e.g., article 1 as illustrated in FIG. 1 or as 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.

[0207] 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 at one end through which an article 110 can be inserted for heating by the heating assembly. In use, the article 110 may be fully or partially inserted into the heating assembly where it may be heated by one or more components of the heater assembly.

[0208] The device 100 of this example includes a first end member 106 with a lid 108 that is movable relative to the first end member 106 closer to the opening 104 when the item 110 is not in position. In Figure 2, the lid 108 is shown in an open configuration; however, 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."

[0209] Device 100 may also include user-operable controls 112, such as buttons or switches, that when pressed operate device 100. For example, a user can activate device 100 by operating switch 112.

[0210] Device 100 may also include an electrical component, such as a socket / port 114, which can receive a cable for charging a battery in device 100. For example, socket 114 may be a charging port, such as a USB charging port.

[0211] In some embodiments, the substance to be delivered may be a composition that includes an aerosol-forming material and a moisture-impermeable coating, as well as another aerosol-forming material that may or may not be heated. Optionally, the composition and other aerosol-forming materials may include one or more active ingredients, one or more fragrances, one or more aerosol-forming materials, and / or one or more other functional materials.

[0212] stability The present invention enjoys the advantage of having a longer shelf life than other tobacco extracts.

[0213] 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 wt% 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% on a dry weight basis.

[0214] 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 may 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.

[0215] Additionally, when surrounded by a moisture impermeable coating, the content of volatile ingredients, such as nicotine and flavorings, in the aerosol-forming material, as well as the content of the aerosol-forming material, is maintained until the composition is heated to generate an aerosol, even without packaging or other protection from exposure to moisture.

[0216] Example 1 In a first test, the precursor material consisted essentially of aqueous tobacco extract and glycerol. The aqueous tobacco extract was further diluted with glycerol to about 24 wt% (calculated on a dry weight basis). The burley aqueous tobacco extract had a tobacco solids content of about 40 wt% and a moisture content of about 60 wt%. The precursor material was dried via freeze drying.

[0217] Example 2 In further testing, the precursor material consisted essentially of aqueous tobacco extract, glycerol and dextran 70. The glycerol content ranged from about 0 to about 15 v / v%, or up to about 36 wt%, calculated on a dry weight basis. The precursor material was dried via lyophilization.

[0218] Example 3 50 mg of the lyophilized aerosol-forming material of Example 1 or Example 2 are agglomerated to form beads having an average size of about 1 mm to about 3 mm. The populations of beads are then each coated by fluidized bed coating with shellac to provide a complete coating having a thickness of about 30 μm.

[0219] Example 4 Ten separate portions, each containing 5 mg of the freeze-dried aerosol-generating material of Example 1 or Example 2, are deposited on the surface of a support containing an aluminum section, which can be heated by magnetic hysteresis heating. Each portion of the aerosol-generating material is coated with a 20 μm thick layer of carnauba wax, lignin or polyvinyl alcohol. The support and the portions containing the aerosol-generating material are then heated to form an aerosol that is inhaled by the consumer.

[0220] Example 5 A tablet is formed by pressing 100 mg of the lyophilized aerosol-forming material of Example 1 or Example 2. The tablet is then spray coated with agar or gum arabic to provide a complete coating having a thickness of about 25 μm.

[0221] 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. It is understood that the advantages, embodiments, examples, functions, features, structures and / or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or equivalents of the claims, and that other embodiments may be utilized and changes may be made without departing from the scope of the invention as claimed. Various embodiments of the present invention may suitably include, consist of, or consist essentially of any suitable combination of elements, components, features, parts, steps, means, etc. of the present disclosure other than those specifically described herein. Furthermore, the present disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. Aerosol generating material comprising a dried precursor material containing an extract derived from a fragrance-containing and / or active plant material, The aerosol-generating material is surrounded by an impermeable coating and A composition containing the following:

2. The composition according to claim 1, wherein the moisture-impermeable coating decomposes when heated, allowing the aerosol-generating material to release volatile components generated by heating.

3. The composition according to claim 2, wherein the moisture-impermeable coating decomposes at a temperature of about 100°C or higher.

4. The composition according to claim 1 or 2, wherein the moisture-impermeable coating comprises one or more selected from the group consisting of polysaccharide or cellulosic materials or derivatives thereof; gum; protein materials; polyol matrix materials; waxes; wax esters; and polymers.

5. The composition according to claim 1 or 2, wherein the moisture-impermeable coating completely encloses the aerosol-generating material.

6. The composition according to claim 1 or 2, wherein the moisture-impermeable coating prevents or delays the absorption of moisture from the surrounding environment by the aerosol-generating material.

7. The composition according to claim 1 or 2, wherein the moisture-impermeable coating has a thickness of about 1 μm to about 100 μm.

8. The composition according to claim 1 or 2, wherein the aerosol generating material is in the form of granules.

9. The composition according to claim 8, wherein the granules have a particle size of about 1 mm to about 4 mm.

10. The composition according to claim 1 or 2, wherein the aerosol generating material is in the form of aggregates or tablets formed from particles.

11. The composition according to claim 10, wherein the aggregate or tablet has a size of about 3 mm to about 20 mm.

12. The composition according to claim 1 or 2, wherein the discrete particles, aggregates, or tablets of the aerosol-generating material are surrounded by the moisture-impermeable coating.

13. The composition according to claim 12, wherein the coatings of different discrete particles, aggregates, or tablets of the aerosol-generating material decompose at different temperatures or rates to control the release of volatile components generated by heating the dry aerosol-generating material.

14. The composition according to claim 13, wherein different discrete particles or portions of the aerosol-generating material are surrounded by coatings of different thicknesses.

15. The composition according to claim 13, wherein different discrete particles or portions of the aerosol-generating material are surrounded by coatings of different coating materials.

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

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

18. 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.

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

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

21. 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.

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

23. 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.

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

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

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

27. 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).

28. The composition according to claim 1 or 2 for use in an aerosol supply system.

29. An article comprising an aerosol-generating material containing a dried precursor material containing an extract derived from a fragrance-containing and / or active-containing plant material, and an impermeable coating surrounding the aerosol-generating material.

30. The article according to claim 29, comprising a film or winding material containing the aforementioned moisture-impermeable coating.

31. The article according to claim 30, wherein the impermeable coating is deposited on a moisture-permeable carrier.

32. The article according to claim 29, comprising the composition according to claim 1.

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

34. A method for providing a composition, comprising: drying a precursor material containing an extract derived from a fragrance-containing and / or active-containing plant material to form an aerosol-generating material; and applying an impermeable coating surrounding the aerosol-generating material.

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

36. The method according to claim 34 or 35, wherein the impermeable coating is applied by a fluidized bed coating process.

37. The method according to claim 34 or 35, wherein the moisture-impermeable coating is formed as part of the drying step.

38. The method according to claim 37, wherein the moisture-impermeable coating-forming material is included in the precursor material.

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