Moisture impermeable container containing aerosol-forming material and use thereof

Abstract

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

Description

[Technical field]

[0001] The present invention relates to a moisture impermeable container containing an aerosol-forming material, a method of making the product and uses thereof. [Background technology]

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

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

[0004] In some embodiments, the moisture impermeable container is opened or removed prior to use of the aerosol forming material to provide access to the aerosol forming material.

[0005] In some embodiments, the container is selected from the group consisting of a wrapper, a pouch, a cartridge, a capsule, and a blister.

[0006] In some embodiments, the container is configured to be punctured, split, or ruptured to provide access to the aerosol-generating material.

[0007] In some embodiments, the container comprises a moisture impermeable sheet material.

[0008] In some embodiments, the container comprises a rupturable capsule configured to rupture when compressed or crushed.

[0009] In some embodiments, the container comprises a moisture impermeable material that decomposes when heated to provide access to the aerosol-forming material.

[0010] In some embodiments, the container comprises one or more moisture impermeable materials selected from the group consisting of polysaccharide or cellulosic materials or derivatives thereof, gums, protein materials, polyol matrix materials, waxes, wax esters, and polymers.

[0011] In some embodiments, the container comprises a single chamber that contains the aerosol-forming material.

[0012] In some embodiments, the container comprises multiple chambers for containing the aerosol-forming materials.

[0013] In some embodiments, the or each chamber contains a portion of aerosol-generating material to provide a single puff of aerosol upon heating.

[0014] In some embodiments, the or each chamber contains a portion of aerosol-generating material to provide multiple puffs of aerosol when heated, optionally the aerosol-generating material when heated provides between 6 and 9 puffs of aerosol.

[0015] In some embodiments, the aerosol-forming material has a moisture content of about 5% or less (calculated on a wet weight basis).

[0016] In some embodiments, the aerosol-forming material is in the form of one or more selected from the group consisting of discrete particles, agglomerates, or tablets.

[0017] In some embodiments, the aerosol-generating material comprises an aerosol-forming material.

[0018] In some embodiments, the precursor material comprises from about 10 to about 95% by weight extract derived from flavor- or active-containing plant material.

[0019] In some embodiments, the precursor material comprises from about 1 to about 36% by weight of the aerosol-forming material.

[0020] In some embodiments, the precursor material comprises from about 0 to about 40% by weight of excipients.

[0021] In some embodiments, the aerosol-forming material comprises from about 45% to about 99% by weight of a dry extract derived from flavor- or active-containing plant material.

[0022] In some embodiments, the aerosol-forming material comprises from about 1 to about 34% by weight of the aerosol-forming material.

[0023] In some embodiments, the aerosol-forming material comprises from about 0 to about 25% by weight of an excipient.

[0024] In some embodiments, the plant material is selected from the group consisting of tobacco, eucalyptus, star anise, cocoa, and hemp.

[0025] In some embodiments, the extract from the flavor-containing or active-containing plant material is an aqueous extract.

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

[0027] In some embodiments, the aerosol-forming material comprises from about 40 to about 99% by weight tobacco solids.

[0028] In some embodiments, the container is for use in an aerosol delivery system.

[0029] According to a second aspect of the present invention there is provided a non-combustion aerosol delivery system comprising a container according to the first aspect and a non-combustion aerosol delivery device.

[0030] In some embodiments, the system is configured to open the container when inserted into the non-combustion aerosol delivery device.

[0031] In some embodiments, the non-combustion aerosol delivery device includes a means for opening the container by puncturing, splitting or rupturing the container.

[0032] In some embodiments, the means for opening the container is actuated by the act of inserting the container into the device.

[0033] In some embodiments, the means for opening the container is actuated by a user.

[0034] In some embodiments, the system is configured to heat the aerosol-generating material to form a vapor and / or an aerosol.

[0035] In some embodiments, the system includes an additional aerosol-generating material that is heated to form an aerosol and / or vapor, and optionally, the additional aerosol-generating material is a liquid.

[0036] In some embodiments, the dry aerosol-forming material is heated by aerosol and / or vapor generated from additional aerosol-forming material.

[0037] In some embodiments, the system includes a means for heating additional aerosol-forming material to form a vapor, but does not include a separate means for heating the dry aerosol-forming material.

[0038] According to a third aspect of the present invention there is provided a method for providing a moisture impermeable container according to the first aspect, comprising the steps of: drying the precursor material comprising an extract from perfume-containing and / or active-containing plant material; placing an aerosol-generating material in a container; and sealing the container.

[0039] In some embodiments, the precursor material is dried by spray drying or freeze drying.

[0040] According to a fourth aspect of the present invention, there is provided a method for providing a moisture impermeable container according to the first aspect, comprising the steps of: placing a precursor material comprising an extract from a perfume-containing and / or active-containing plant material in a container; drying the precursor material; and sealing the container.

[0041] In some embodiments, the precursor composition and / or the aerosol-forming material comprises an aerosol-forming material.

[0042] In some embodiments, the method includes coating an exterior surface of the container with a moisture impermeable coating.

[0043] 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]

[0044] [Figure 1] FIG. 1 is a schematic diagram of a moisture impermeable pouch for holding aerosol-forming materials. [Diagram 2] FIG. 2 is a cross-sectional view of a strip of moisture impermeable blisters holding aerosol-forming material. [Diagram 3] 1 is a side cross-sectional view of a first embodiment of a consumable product including a container as described herein. [Figure 4] FIG. 4 is a perspective view of a non-combustion aerosol delivery device for generating aerosol from the consumable shown in FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0045] An aerosol-forming material is a material that is capable of generating an aerosol when, for example, heated, irradiated, or in any other way energized.

[0046] 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.

[0047] 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.

[0048] The present invention relates to a moisture impermeable container containing a dry or dehydrated aerosol forming material formed from an extract derived from fragrance-containing and / or active-containing plant material.

[0049] Although some consumables are known to include a wrapper that surrounds the aerosol-forming material, this wrapper is typically paper and does not provide a moisture-impermeable container to protect the aerosol-forming material from moisture in the surrounding environment.

[0050] In some embodiments, the extract is a liquid solution or suspension and may be dried or dehydrated using processes such as spray drying or freeze drying. The dried or dehydrated aerosol-forming material may be formed from precursor materials that include an extract from flavor-containing and / or active-containing plant material and an aerosol-forming material.

[0051] Aerosol-forming materials that include dried extracts from fragrance-containing and / or active-containing plant materials contain high concentrations of fragrances and / or actives, with little or no material contributing to the aerosol generated from the dry aerosol-forming material. Thus, small amounts of aerosol-forming material are sufficient to generate an aerosol with the desired active and fragrance content. Furthermore, the aerosol may be generated with a relatively low level of energy input.

[0052] 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.

[0053] In some embodiments, the dry aerosol-forming material in the moisture-impermeable pack has a moisture content (calculated on a wet weight basis) of 0 to about 10%, or 0 to about 5%, 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.

[0054] 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.

[0055] Unless otherwise stated, references to water content herein are references to water content as measured by Karl Fischer titration.

[0056] 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.

[0057] 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.

[0058] Preventing or reducing the absorption of water by the aerosol-forming material also helps manage or avoid the phenomenon known as "hot puffs."

[0059] In the present disclosure, a moisture-impermeable container is provided that contains an aerosol-forming material. The container prevents exposure of the aerosol-forming material to moisture, and therefore prevents absorption of moisture by the aerosol-forming material prior to its use. The container may also be hermetically sealed.

[0060] Ideally, the aerosol-forming material is sealed in a moisture-impermeable container immediately after its manufacture or preparation. If there is a delay in packaging the aerosol-forming material, the material should be kept in a controlled, low humidity environment.

[0061] In some embodiments, packaging the portion of the aerosol-forming material in a moisture-impermeable container is performed in a controlled, low humidity environment to minimize moisture absorption by the aerosol-forming material before the aerosol-forming material is sealed in the container.

[0062] Thus, there is provided a moisture-impermeable container comprising an aerosol-forming material comprising a dry precursor material comprising an extract from a fragrance-containing and / or active-containing plant material, and optionally an aerosol-forming material, and a moisture-impermeable housing surrounding the aerosol-forming material.

[0063] In some embodiments, the hygroscopic aerosol-forming material in the moisture-impermeable container 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 it is first prepared, but also after it is incorporated into the container, transported, and stored. This stable water content is observed despite the fact that the hygroscopic aerosol-forming material rapidly absorbs water when exposed to the environment, even under "normal" humidity conditions. Indeed, when an aerosol-forming material is described as hygroscopic, this means that it rapidly absorbs water from the surrounding environment, significantly increasing its water content. For example, when the aerosol-forming material is exposed to the environment (e.g., upon storage in an open container, etc.), the water content rapidly increases to more than 20% or more than 25% (calculated on a wet weight basis) as measured by gas chromatography-thermal conductivity detector (GC-TCD) or Karl Fischer titration.

[0064] Moisture-impermeable container The moisture-impermeable containers disclosed herein form a moisture-impermeable barrier around the aerosol-forming material formed by drying an extract from a fragrance-containing and / or active-containing plant material, which is important because dry aerosol-forming materials have a strong tendency to absorb moisture from their environment, resulting in the adverse effects mentioned above.

[0065] Conventional aerosol-generating materials do not usually need to be provided in moisture-impermeable containers to protect them from moisture. This is because conventional aerosol-generating materials are not hygroscopic and are not particularly sensitive to moisture. The highly concentrated nature of dry aerosol-generating materials means that absorption of even small amounts of moisture can be very detrimental to the properties of the aerosol-generating materials and the quality of the aerosols generated.

[0066] In some embodiments, the moisture impermeable container is opened or removed prior to use of the aerosol-generating material, allowing access to the aerosol-generating material and allowing components released from the material during use to exit the container. For example, in embodiments in which the aerosol-generating material is heated to form an aerosol, the container must be opened or removed to allow the aerosol to exit the container.

[0067] In some embodiments, the moisture impermeable container is selected from the group consisting of a wrapper, a pouch, a cartridge, a pod, a capsule, and a blister. In some embodiments, the container contains a single consumable, and the container is opened or removed prior to or during use. In other embodiments, the container contains multiple consumables or portions of aerosol-generating materials. In such embodiments, the container may be configured to be resealable, such that the consumable or portion remaining in the container can remain protected from moisture even after the container is opened to remove the consumable or portion.

[0068] The wrapper or pouch may be flexible and may be formed, for example, from one or more moisture impermeable sheets. Once a portion of the aerosol-generating material has been added, the sheets may be joined together to seal the wrapper or pouch. The wrapper or pouch forms a chamber in which the aerosol-generating material is sealed. In some embodiments, the moisture impermeable sheet is formed from or consists of a moisture impermeable material. For example, the moisture impermeable sheet may include or consist of a metal sheet such as aluminum foil or a high moisture barrier plastic (e.g., ACLAR® (a moisture and nicotine resistant fluoropolymer film)). In other embodiments, the sheet material includes a moisture permeable or porous material that is covered or coated with a layer of moisture impermeable material. Such a sheet may include a laminate of a material such as paper / pulp laminated with a moisture resistant material (e.g., varnish). In some embodiments, the flexible sheet does not include polypropylene or polystyrene.

[0069] The pouch may be provided as a single pouch or as a series of connected pouches, each pouch holding an aerosol generating material to provide a single puff or a series of puffs of aerosol. The multiple pouches may all hold the same aerosol generating material or two or more different aerosol generating materials. A series of connected pouches may be configured such that a single pouch can be separated from the rest and inserted into the aerosol delivery device. Alternatively, a series of connected pouches may be received within the device and opened and used sequentially.

[0070] An example of a moisture impermeable pouch is shown in Figure 1. The pouch 1 includes two sheets 2 of a porous material that has been coated to make the sheets moisture impermeable. The sheets are fused or glued along their edges to form a chamber in which the aerosol-generating material 3 is sealed.

[0071] In other embodiments, the container is a cartridge or blister. The cartridge or blister may include a rigid or semi-rigid body defining an open chamber in which the aerosol-generating material is held. In some embodiments, the rigid or semi-rigid body is molded. The body may be formed from a moisture-impermeable material, such as a suitable polymeric, plastic, or metallic material. In other embodiments, the body may be formed from a moisture-impermeable material that is made moisture-impermeable by virtue of a moisture-impermeable cover or coating. For example, the body may include molded paper / pulp for an environmentally friendly cartridge or blister.

[0072] In some embodiments, the cartridge may be moved between open, closed and sealed configurations so that aerosol-generating material can be added and then sealed inside the cartridge. Upon use, the cartridge is re-opened to allow access to the aerosol-generating material and to release the aerosol generated upon use.

[0073] In some embodiments, the cartridge or blister includes an opening that can be temporarily sealed, for example by a stopper or cover. For example, a cover suitable for sealing the opening may include a sheet material, such as a moisture impermeable sheet material as described above. The sheet material may be attached to the edge of the opening, for example using an adhesive or by welding.

[0074] The blister may be provided as a single blister or as multiple connected blisters, each holding an aerosol generating material to provide a single puff or a series of puffs of aerosol. The multiple blisters may all hold the same aerosol generating material or two or more different aerosol generating materials. The multiple blisters may be configured such that a single blister can be separated from the rest and inserted into the aerosol delivery device. Alternatively, multiple connected blisters may be received in the device and opened and used sequentially.

[0075] The multiple blisters may be formed from a single rigid or semi-rigid body shaped to provide multiple open chambers, each holding a portion of the aerosol-generating material. The openings of the chambers may be sealed with a single moisture impermeable sheet. The chambers may be arranged in a linear arrangement, or in a circle, or in any other configuration.

[0076] An example of a moisture impermeable blister strip is shown in Figure 2. Blister strip 11 includes a series of connected blisters. The blister strip is formed from a molded body portion 12 that forms a series of open chambers into which aerosol-forming material may be placed before the chambers are sealed by a moisture impermeable sheet 13, such as a metal foil. The moisture impermeable sheet 13 is welded to the molded body portion 12 to form a series of sealed chambers that hold the aerosol-forming material. The blisters may be opened by piercing or cutting the moisture impermeable sheet 13 with a blade or the like.

[0077] In a further embodiment, the container is a capsule, which may take the form of a rigid or semi-rigid shell defining a chamber in which the aerosol-forming material is held.

[0078] The capsule shell material may, in some cases, be moisture impermeable. In other embodiments, the shell may be coated with a moisture impermeable coating. In some embodiments, the capsule may be ruptured (i.e., crushed) to open the container and access the contents, allowing the aerosol generated from the aerosol-generating material to be released. In such embodiments, the capsule shell material is frangible or breakable. For example, the capsule may be crushed or otherwise broken or destroyed by a user to open the container and access its contents.

[0079] Crushing of the capsule may occur, for example, before the capsule is inserted into an aerosol generating device. In some embodiments, the shell may be ruptured under pressure applied by a user's finger (or any other pressure generating means) when the user is ready to use the aerosol generating contents of the capsule. In some embodiments, the capsule is crushed by the user during use to enhance flavor at some point during use of the aerosol delivery system.

[0080] In some cases, the capsules may have a crush strength of from about 0.8 kp to about 3.5 kp, suitably from about 1.0 kp to about 2.5 kp or from about 1.0 to about 2.0 kp.

[0081] In some cases, the capsules described herein may be substantially spherical and have a diameter of at least about 0.4 mm, 0.6 mm, 0.8 mm, 1.0 mm, 2.0 mm, 2.5 mm, 2.8 mm, or 3.0 mm. The diameter of the capsule may be less than about 10.0 mm, 8.0 mm, 7.0 mm, 6.0 mm, 5.5 mm, 5.0 mm, 4.5 mm, 4.0 mm, 3.5 mm, or 3.2 mm. Illustratively, the capsule diameter may range from about 0.4 mm to about 10.0 mm, from about 0.8 mm to about 6.0 mm, from about 2.5 mm to about 5.5 mm, or from about 2.8 mm to about 3.2 mm. In some cases, the capsule may have a diameter of about 3.0 mm to about 3.5 mm.

[0082] In some embodiments, the shell comprises about 5 to about 90% by weight of the gelling agent, based on the total capsule shell weight. In some cases, the shell comprises about 5 to about 60% by weight, about 5 to about 50% by weight, or about 10 to about 35% by weight of the gelling agent, based on the total capsule shell weight.

[0083] Suitable gelling agents that may be included in the capsule shell material may include, but are not limited to, polysaccharide or cellulosic gelling agents, gelatin, gums, gels, waxes, or mixtures thereof. Suitable polysaccharides include alginates, dextran, maltodextrin, cyclodextrin, carrageenan, and pectin. Suitable alginates include, for example, salts of alginic acid, esterified alginates, or glyceryl alginates. In some examples, the barrier material includes sodium alginate and / or calcium alginate. Suitable cellulosic materials include methylcellulose, ethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose, cellulose acetate, and cellulose ethers. The gelling agent may include one or more modified starches. The gelling agent may include one or more carrageenans. Suitable gums include agar, gellan gum, gum arabic, pullulan gum, mannan gum, gum ghatti, gum tragacanth, karaya, locust bean, acacia gum, guar, quince seed, and xanthan gum. Suitable gels include agar, agarose, carrageenan, freudan, and furcellaran. Suitable waxes include carnauba wax. In some cases, the gelling agent may include carrageenan and / or gellan gum. These gelling agents are particularly suitable for inclusion as gelling agents because the pressure required to break the resulting capsule is particularly suitable. In some cases, the capsule shell does not include gelatin.

[0084] The capsule shell may further comprise one or more of a bulking agent, a buffering agent, a coloring agent, and a plasticizer. The plasticizer may be selected from the group consisting of glycerol, sorbitol, maltitol, triacetin, polyethylene glycol, propylene glycol or another polyhydric alcohol having plasticizing properties, and optionally an acid of the mono-, di- or tri-acid type, in particular citric acid, fumaric acid, malic acid, and the like. In some cases, the amount of plasticizer ranges from about 1 to about 30% by weight, about 2 to about 15% by weight, or about 3 to about 10% by weight of the total weight of the shell. In some cases, the total amount of plasticizer and gelling agent combined in the shell is about 40 to 70% by weight, suitably about 50 to 60% by weight, based on the total weight of the capsule shell. In some cases, the plasticizer comprises, consists essentially of, or consists of glycerol.

[0085] The capsule shell may include a hydrophobic outer layer that enhances the moisture resistance of the container. The hydrophobic outer layer is suitably selected from the group including wax, particularly carnauba wax, candelilla wax or beeswax, carbowax, shellac (in alcohol or aqueous solution), ethyl cellulose, hydroxypropyl methylcellulose, hydroxylpropyl cellulose, latex compositions, polyvinyl alcohol, or combinations thereof. In some embodiments, at least one moisture barrier agent is ethyl cellulose or a mixture of ethyl cellulose and shellac.

[0086] The containers described herein may be opened before the aerosol generating material held therein is used. For example, a user may manually open the container and optionally remove the aerosol generating material. In other embodiments, the container may be opened when inserted into an aerosol generating device. For example, the device may include means for puncturing or splitting the pouch, which acts as a result of the act of inserting the container into the device. Alternatively, the opening means may be separately actuated, for example by a user, when the device is used to generate aerosol.

[0087] In other embodiments, the container can be opened when exposed to heat. For example, the container or a portion thereof can decompose when heated to provide access to the aerosol-generating material. In some embodiments, the opening of the container body can be closed with a stopper or sheet comprising a material that decomposes when heated. In some embodiments, the container can include a porous material surrounded by or coated with a moisture-impermeable layer that decomposes at the temperatures to which the container and aerosol-generating material are exposed during use. Decomposition of the temperature-sensitive moisture-impermeable material renders the container moisture-permeable, allowing the aerosol generated by the aerosol-generating material to be released from the container.

[0088] In some embodiments, degradation of a coating or material upon heating involves losing its physical integrity such that it no longer forms a moisture impermeable barrier, which may involve, for example, melting, disappearing, disintegrating, or otherwise decomposing the coating.

[0089] It may be expected that the integrity of the moisture-impermeable container may be compromised when the material forming at least a part of the container is heated to its melting point. Thus, the material should be selected so that it remains intact when the moisture-impermeable container is exposed to normal environmental temperatures. Thus, in some embodiments, the material used must be one that forms a stable moisture-impermeable coating at temperatures below 40 or 50° C. In some embodiments, it may be desirable to select a material that forms a moisture-impermeable coating or part that remains intact during the more extreme temperatures that may be encountered during storage and transportation, for example temperatures of 60 to 80° C.

[0090] In some embodiments, the container comprises a heat-sensitive, moisture-impermeable material that becomes moisture-permeable when the temperature is increased to about 100-110° C. to avoid overheating of moisture present in the aerosol-forming material held within the container. In some embodiments, the container opens rapidly upon heating to form the aerosol. This reduces the likelihood that the container will impede volatilization and the resulting release of gas or vapor.

[0091] In some embodiments, the temperature at which the thermally impermeable material becomes moisture permeable, for example as a result of decomposition, is at least about 50°C, at least about 60°C, at least about 70°C, at least about 80°C, at least about 90°C, at least about 100°C, at least about 110°C, at least about 120°C, at least about 130°C, at least about 140°C, at least about 150°C, at least about 160°C, at least about 170°C, at least about 180°C, at least about 190°C, or at least about 200°C.

[0092] Additionally or alternatively, the temperature at which the thermally impermeable material becomes moisture permeable, for example as a result of decomposition, is about 280°C or less, about 270°C or less, about 260°C or less, about 250°C or less, about 240°C or less, about 230°C or less, about 220°C or less, about 210°C or less or 200°C or less, about 190°C or less, about 180°C or less, about 170°C or less, about 160°C or less, about 150°C or less, about 140°C or less, about 130°C or less, about 120°C or less, about 110°C or less, or about 100°C or less.

[0093] In some embodiments, the thermally sensitive moisture impermeable coating or material 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.

[0094] 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.

[0095] If the container includes a moisture impermeable coating, the coating is of sufficient thickness to impart the desired moisture impermeability. The thickness of the coating, in some embodiments, further influences the temperature at which the coating becomes moisture permeable, allowing volatile components generated by heating the aerosol-forming material to be released from the container.

[0096] In some embodiments, the thickness of the coating can also affect the rate at which the coating becomes moisture permeable once exposed to decomposition temperatures, which can allow for control of the release rate of volatile components from the heated aerosol-forming material.

[0097] When multiple containers are provided together, it may be desirable for these to be opened independently of one another, with each container remaining moisture impermeable until its contents are used.

[0098] In some embodiments, the container contains one or more additives that are released during heating to generate aerosol, and thus contribute to the generated aerosol. Such additives may be included, for example, in a coating or sheet material that forms part of the container. In some embodiments, the container contains an active material, including one or more of the active materials described elsewhere herein. Additionally or alternatively, the container contains a fragrance, including one or more of the fragrances and flavorings described elsewhere herein. In some embodiments, the fragrance is a hydrophobic fragrance. This may mean that the fragrance further increases the moisture impermeability of the container.

[0099] In some cases, the total mass of aerosol-forming material contained in the container 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.

[0100] 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.

[0101] 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.

[0102] The container has suitable dimensions to accommodate this amount of aerosol-forming material, yet is also of a size that is easy to manufacture and handle.

[0103] In some embodiments, the aerosol-generating material may be incorporated into the container without a carrier or other substrate material that requires heating. In some embodiments, the aerosol-generating material is provided in the form of a loose powder. In other embodiments, the aerosol-generating material is provided in the form of multiple beads or granules, or in the form of a single tablet.

[0104] In some embodiments, the aerosol-generating material is in the form of beads having a size of up to about 4 mm (as measured by sieving). Alternatively or additionally, the aerosol-generating material may be in the form of particles or granules pressed into the form of tablets having a size of from about 1 to about 4 mm.

[0105] However, in some embodiments, the aerosol-forming material may be applied to a carrier or substrate before being placed in the container. The substrate may, for example, be another, different aerosol-forming material.

[0106] 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.

[0107] In some embodiments, the aerosol-generating material is formed by drying a precursor material that includes an extract from a flavor-containing and / or active-containing plant material. The drying process is selected to preserve desired components of the precursor material, and thus the aerosol-generating material may include one or more actives and / or flavors.

[0108] In some embodiments, the extract from the perfume-containing or active-containing plant material is an extract obtained by contacting the plant material with a suitable solvent, such as an aqueous solvent or an alcohol, such as ethanol, and the liquid portion containing the solvent and any dissolved plant components is then separated or partially separated from the remaining solid plant material to provide the extract contained in the precursor composition, which can then be dried.

[0109] 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.

[0110] The precursor material and / or the dry aerosol forming material may also optionally include one or more other functional materials.

[0111] Thus, the aerosol-generating material may include one or more active agents and / or flavorings, and optionally one or more aerosol-forming materials. The precursor material and / or the dry aerosol-generating material may also optionally include one or more other functional materials.

[0112] The present invention takes advantage of aerosol generating materials that are formulated to have a long shelf life and therefore can be easily transported and stored. Without wishing to be bound by any particular theory, it is hypothesized that the low moisture content of the dry aerosol generating materials reduces the evaporation of other solvents over time and reduces the decomposition of nicotine and / or other volatile compounds. The low moisture content also inhibits microbial growth. Compositions including the dry aerosol generating materials described herein are stable over a range of temperatures and humidities, resulting in a long shelf life and therefore easy to store and transport. In some embodiments, the compositions can be stored at temperatures ranging from 0 to 35°C. In some embodiments, the compositions can be stored at up to about 50% relative humidity, and in some cases as high as 90% RH, prior to use.

[0113] Aerosol-generating materials also have the advantage of having a high concentration of the desired components, meaning that a relatively small amount of the aerosol-generating material is needed and less energy is needed to heat and release the desired components. Importantly, the aerosols generated from these materials also provide a reasonable intensity of authentic tobacco flavor.

[0114] 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.

[0115] In some embodiments, the extract from flavorant- or active-containing plant material is an extract from tobacco material.

[0116] 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.

[0117] 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).

[0118] In some embodiments, the precursor material comprises at least about 10% by weight, at least about 20% by weight, at least about 30% by weight, at least about 40% by weight, at least about 50% by weight, at least about 60% by weight, at least about 70% by weight, at least about 80% by weight, or at least about 90% by weight of an extract derived from tobacco or other flavor- or active-containing plant material (calculated on a wet weight basis). Alternatively or additionally, the precursor material may comprise up to about 99% by weight, up to about 90% by weight, up to about 80% by weight, up to about 70% by weight, or up to about 60% by weight of an extract derived from tobacco or other flavor- or active-containing plant material (calculated on a wet weight basis). In some embodiments, the precursor material comprises about 50% by weight of a tobacco extract (calculated on a wet weight basis).

[0119] In some embodiments, the aerosol-forming material may comprise at least about 45%, at least about 50%, at least about 60%, at least about 70%, at least about 80%, at least about 90%, or at least about 95% by weight of tobacco material or tobacco extract, or flavorant- or active-containing plant material extract (calculated on a dry weight basis). In some embodiments, the aerosol-forming material may comprise from about 60 to about 80% by weight of tobacco extract (calculated on a dry weight basis).

[0120] 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).

[0121] 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.

[0122] 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).

[0123] 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).

[0124] 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.

[0125] 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.

[0126] 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.

[0127] 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.

[0128] In some embodiments, the dry aerosol-generating material and / or the precursor material includes one or more active agents, which may be obtained from an extract or may be added. In some embodiments, an extract from a flavored or active-containing plant material includes the active agents.

[0129] 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.

[0130] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0131] In some embodiments, the precursor material may include extracts from other plant source(s) along with or in place of tobacco extract.

[0132] As described herein, an extract may comprise or be derived from one or more plants or components, derivatives or extracts thereof. As used herein, the term "botanical" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fiber, stems, roots, seeds, flowers, fruits, pollen, husks, shells, etc. Extracts may comprise or be derived from plants in the form of liquids, gases, solids, powders, dusts, crushed particles, granules, pellets, shreds, strips, sheets, etc. Exemplary botanicals include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, bay, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea, such as green or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, Lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiane, marjoram, olive, lemon balm, lemon basil, chives, Calvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. The mint may be selected from the following mint varieties: Mentha americana, Mentha cv, Egyptian mint, Mentha piperita, Eau de cologne mint, Candy mint, Curly mint, Kentucky kernel mint, Horse mint, Pineapple mint, Pennyroyal mint, Green mentha, and Apple mint.

[0133] 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.

[0134] 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.

[0135] 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).

[0136] 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).

[0137] The aerosol-generating material and / or precursor material may include cannabidiol (CBD).

[0138] The aerosol generating and / or precursor materials may include nicotine and cannabidiol (CBD).

[0139] The aerosol-generating and / or precursor materials may include nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol).

[0140] The aerosol-generating material further comprises an aerosol-forming material, which in some embodiments is included in the precursor material.

[0141] 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.

[0142] 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.

[0143] 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.

[0144] 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.

[0145] Combinations of two or more aerosol forming agents may be used, in equal or differing proportions.

[0146] 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).

[0147] 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.

[0148] 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.

[0149] 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.

[0150] 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).

[0151] 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).

[0152] 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.

[0153] 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.

[0154] Suitable excipients include mannitol, sucrose, trehalose, lactose, sorbitol, raffinose, maltose, dextran 10, dextran 70, dextran 90, maltodextrin, gelatin, agar, cyclodextrin, and polyethylene glycols such as PEG 2000-6000 and polyvinylpyrrolidone (PVP10k).

[0155] 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.

[0156] 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).

[0157] 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.

[0158] 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.

[0159] 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.

[0160] 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.

[0161] 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.

[0162] 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 through 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.

[0163] [Table 1]

[0164] The nicotine content in the formulation depends on the type of tobacco used and the presence of other components, namely aerosol formers and excipients.

[0165] 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.

[0166] In some embodiments, the aerosol-generating and / or precursor materials include one or more flavor modifiers, flavors, or flavorings, which may be derived from extracts or may be added. As used herein, the terms "flavor" and "flavoring" refer to materials that may be used, where local regulations permit, to create a desired taste, odor, or other somatic sensation in a product intended for adult consumers.They may be any naturally occurring flavoring material, botanical substance, extracts of botanical substances, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherries, berries, red berries, cranberries, peaches, apples, oranges, mangoes, clementines, lemons, Lime, tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, eggplant, betel quid, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, Ylang-ylang, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, peppermint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, bay, yerba mate, orange peel, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, black currant, valerian, pimento, mace, damienne , marjoram, olive, lemon balm, lemon basil, chives, Calvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners.They may be of imitation, synthetic, or natural origin, or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas.

[0167] 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.

[0168] 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.

[0169] 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.

[0170] 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.

[0171] 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.

[0172] 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.

[0173] 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.

[0174] 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.

[0175] 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.

[0176] 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.

[0177] 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.

[0178] 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.

[0179] 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.

[0180] 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.

[0181] 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).

[0182] In some embodiments, the aerosol-generating material is in the form of granules. The granules can be of any size, cross-sectional shape, or mass. Aerosol-generating materials in the form of granules are advantageous due to their high surface area to volume ratio, which positively impacts the release of volatile substances from the material. This form also facilitates the incorporation of the material into an aerosol delivery system.

[0183] 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.

[0184] Smaller granule particles have a greater surface area to volume ratio and therefore may exhibit enhanced release of tobacco constituents as compared to larger sized particles.

[0185] In some embodiments, the particles in the precursor composition have an average particle size of about 3 mm or less, 1 mm or less, about 0.5 mm or less, or desirably about 0.3 mm or less, as measured by sieving.

[0186] 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.

[0187] When preparing the dried precursor composition, the particle size of any solid material present can be reduced by grinding, shredding, cutting or crushing the plant material. Suitable machines for making such plant particles include, for example, shredders, cutters, or mills, such as hammer mills, roller mills or other types of commercially available milling machines. The size of the plant particles is selected to result in particles that can be readily prepared from a variety of different types of plant material having the characteristics described herein and that provide a source of readily releasable plant components.

[0188] 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.

[0189] 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.

[0190] 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.

[0191] 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.

[0192] 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.

[0193] 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.

[0194] In a small scale example, the precursor material is freeze-dried using a freeze-drying microscope, for example a Lyostat freeze-drying microscope.

[0195] 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.

[0196] 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.

[0197] 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.

[0198] 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.

[0199] 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.

[0200] 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.

[0201] In some embodiments, the precursor material can be placed in a container and dried in situ to form the aerosol-generating material in a container that is then sealed. In such embodiments, a preferred drying process can be freeze-drying. This in situ drying of the precursor material can minimize exposure of the aerosol-generating material to moisture prior to opening the container immediately prior to or during use.

[0202] Use of containers The container containing the aerosol-forming material may be used in a combustion or non-combustion aerosol delivery system, or in a delivery system that does not include an aerosol.

[0203] In some embodiments, the container may hold, in addition to the aerosol-forming material, a further, different aerosol-forming material, such as tobacco material in the form of cut rag or reconstituted tobacco material.

[0204] In some embodiments, the container further comprises, in addition to the aerosol-generating material, a heating material comprising one or more materials selected from the group consisting of an electrically conductive material, a magnetic material, and a magnetically conductive material. In some embodiments, the heating material may comprise a metal or a 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.

[0205] 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.

[0206] In some embodiments, the container is used as or is included in a consumable product.

[0207] A consumable is an article that includes an aerosol-generating material, some or all of which is intended to be consumed during use by a user, where the aerosol-generating material, or at least a portion of the aerosol-generating material, is provided in a container as disclosed herein.

[0208] The consumable may comprise one or more other components, such as an aerosol-generating material storage region, an aerosol-generating material transport component, an aerosol-generating region, a housing, a wrapper, a mouthpiece, a filter, and / or an aerosol modifier.

[0209] An example of a consumable including a moisture-impermeable capsule is shown in FIG. 3. The consumable 20 is rod-shaped and consists of separate abutting sections held together by a wrapper 26. One section includes a moisture-impermeable capsule 21 containing the aerosol generating material. The capsule 21 has a frangible shell with a moisture-impermeable coating. This is shown surrounded by a support material. The frangible capsule can be ruptured by a user squeezing a section of the consumable before inserting the consumable into an aerosol generating device. The consumable can have suitable markings around the wrapper 26 to indicate where the squeezing pressure should be applied. The middle section is a cooling section 23 comprising a hollow tube formed from a suitable material such as cellulose acetate, paper or heat-absorbing material. The third (mouth end) section is a filter section including a plug of filter material 24.

[0210] The consumable may also include an aerosol generator, such as a heater that generates heat during use to cause the aerosol-generating material to generate an aerosol. The heater may include, for example, a combustible material, a material heatable by electrical conduction, or a susceptor. The heater, in some embodiments, may be provided within the container along with the aerosol-generating material. In some embodiments, the heater may form part of the housing of the container.

[0211] In some embodiments, at least a portion of the container is made from a thermally conductive material to facilitate heating of the aerosol-forming material held therein.

[0212] The consumable may be of any shape or size suitable for a smoking device. In a preferred embodiment of the invention, the consumable is rod shaped.

[0213] In some embodiments, the container containing the aerosol-forming material is provided in an aerosol-generating device, such as a tobacco heating product (THP) or a hybrid e-cigarette product. Suitably, the container may be used directly as a solid substrate, where the container is heated directly without combustion to provide an inhalable aerosol.

[0214] In some embodiments, heating the container first causes the moisture impermeable material or coating to degrade, breaching the barrier that it forms around the aerosol-forming material, and then releases the aerosolized components of the aerosol-forming material, such as glycerol, nicotine, and / or tobacco flavors.

[0215] In some embodiments, inserting the container into the aerosol generating device opens the container to allow access to the aerosol generating material. For example, the act of insertion may result in activation of a means for opening the container. In a different embodiment, the container is opened after it is inserted into the device. In such an embodiment, the means for opening the container may be activated, for example, by a user.

[0216] The means for opening the container may involve, for example, applying a compressive force to rupture the container or a portion thereof. Alternatively, the means for opening the container may comprise one or more sharp protrusions in a device that are brought into contact with the container to rupture, puncture or split the container. One or more openings may be created in the container.

[0217] Once the container is opened, the aerosol-forming material is no longer protected by the housing and can absorb moisture from the environment to which it is exposed.

[0218] Because the container protects moisture sensitive aerosol forming materials, there is no need to store the container or consumable in low humidity conditions prior to use.

[0219] 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.

[0220] 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.

[0221] 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.

[0222] Delivery System The delivery systems described herein can be combustion aerosol delivery systems, non-combustion aerosol delivery systems, or aerosol-free delivery systems.

[0223] 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.

[0224] 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.

[0225] 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.

[0226] 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.

[0227] 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.

[0228] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0229] 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.

[0230] 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.

[0231] 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, 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 includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, a tobacco or non-tobacco product.

[0232] 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.

[0233] In some embodiments, the present disclosure relates to consumables that include a container containing an aerosol-generating material and that are configured for use with a non-combustion aerosol delivery device. These consumables may be referred to as articles throughout this disclosure.

[0234] 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 composition including the aerosol generating material and the moisture impermeable coating or to a heat transfer material in proximity to the heat generating power source.

[0235] 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.

[0236] In some embodiments, a consumable for use with a non-combustion aerosol delivery device may include a composition including an aerosol-generating material and a moisture impermeable coating, an aerosol-generating material storage region, an aerosol-generating material transport component, an aerosol generator, an aerosol-generating region, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0237] 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 an article 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.

[0238] 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 the article 110 can be inserted for heating by the heating assembly. In use, the article 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. The article 110 is shown having a rod shape, similar to the consumable 20 shown in FIG. 3. However, the article can have a different shape and be a container as shown in FIG. 1 or FIG. 2 with an appropriately adapted device and opening.

[0239] 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."

[0240] Device 100 may also include a user-operable control element 112, such as a button or switch that, when pressed, operates device 100. For example, a user may turn on device 100 by operating switch 112. The switch may also activate a means for opening a container inserted into the device in preparation for its use.

[0241] 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.

[0242] In some embodiments, the substance to be delivered may be an aerosol-generating material provided in a container, and optionally another aerosol-generating material that may or may not be heated. If desired, the aerosol-generating material in the container and any 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.

[0243] stability The present invention enjoys the advantage of a longer shelf life than other tobacco extracts.

[0244] 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.

[0245] 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.

[0246] 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.

[0247] 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.

[0248] 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.

[0249] Example 3 To evaluate possible containers for use in the present invention, an amount of the aerosol-forming material of Example 1 or 2 is placed in a moisture-impermeable container and weighed. The container is then exposed to 90% relative humidity. After 10 days, the container is weighed again, and the increase in weight can be attributed to the absorption of moisture from the environment by the aerosol-forming material. A completely moisture-impermeable container shows no weight change.

[0250] Example 4 The freeze-dried material of Example 1 or Example 2 is ground to obtain a loose powder with an average size of about 1 mm to about 3 mm. 50 mg of the powder is then placed in the chamber of a blister under nitrogen, and the opening of the blister is then sealed with a sheet of ACLAR® 33C film (a 199 μm thick copolymer film based on chlorotrifluoroethylene (CTFE)).

[0251] Example 5 100 mg of the freeze-dried material of Example 1 or Example 2 is pressed to form a tablet. The tablet is then placed, under nitrogen, inside an open pouch formed by folding an aluminum sheet and sealing along two edges. The pouch is then closed by sealing along the open edge.

[0252] The various embodiments described herein are presented only to aid in the understanding and teaching of the claimed features. These embodiments are provided only as a representative sample of embodiments and are not exhaustive and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be considered as limitations on the scope of the invention as defined by the claims or limitations on the equivalents of the claims, and it is understood that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the present invention may suitably comprise, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, the present disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

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

2. The container according to claim 1, wherein the moisture-impermeable container is opened or removed before use of the aerosol-generating material in order to provide access to the aerosol-generating material.

3. A container according to claim 1 or 2, selected from the group consisting of wrappers, pouches, cartridges, capsules, and blisters.

4. The container according to claim 1 or 2, configured to be perforated, divided, or ruptured to provide access to the aerosol-generating material.

5. The container according to claim 1 or 2, comprising an impermeable sheet material.

6. The container according to claim 1 or 2, comprising a burstable capsule configured to rupture when compressed or crushed.

7. The container according to claim 1 or 2, comprising a moisture-impermeable material that decomposes upon heating to provide access to the aerosol-generating material.

8. The container according to claim 7, comprising one or more moisture-impermeable materials selected from the group consisting of polysaccharides or cellulosic materials or derivatives thereof; gums; protein materials; polyol matrix materials; waxes; wax esters; and polymers.

9. The container according to claim 1, comprising a single chamber for containing the aerosol generating material.

10. The container according to claim 1, comprising a plurality of chambers for containing the aerosol generating material.

11. The container according to claim 9 or 10, wherein the chamber or each chamber contains a portion of the aerosol-generating material to supply a single puff of aerosol when heated.

12. The container according to claim 9 or 10, wherein the chamber or each chamber contains a portion of an aerosol generating material to supply a plurality of aerosol puffs when heated, and optionally, when the aerosol generating material is heated, it supplies 6 to 9 puffs of aerosol.

13. The container 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).

14. The container according to claim 1 or 2, wherein the aerosol generating material is one or more forms selected from the group consisting of individual particles, aggregates, or tablets.

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

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

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

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

19. The container 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.

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

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

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

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

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

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

26. A container according to claim 1 or 2 for use in an aerosol supply system.

27. A non-combustible aerosol supply system comprising the container and non-combustible aerosol supply device according to claim 1 or 2.

28. The non-combustible aerosol supply system according to claim 27, wherein the system is configured to open the container when the container is inserted into the non-combustible aerosol supply device.

29. The non-combustible aerosol supply system according to claim 28, wherein the non-combustible aerosol supply device includes means for opening the container by puncturing the container, dividing the container, or rupturing the container.

30. The non-combustible aerosol supply system according to claim 29, wherein the means for opening the container is activated by an action of inserting the container into the device.

31. The non-combustible aerosol supply system according to claim 29, wherein the means for opening the container is operated by a user.

32. The non-combustion aerosol supply system according to claim 29, wherein the system is configured to heat the aerosol-generating material to form steam and / or aerosol.

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

34. The non-combustion aerosol supply system according to claim 33, wherein the dry aerosol generating material is heated by the aerosol and / or vapor generated from the further aerosol generating material.

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

36. A method for providing a moisture-impermeable container according to claim 1 or 2, Drying a precursor material containing an extract derived from a fragrance-containing and / or active plant material, The aerosol generating material is placed inside the container, A method comprising sealing the aforementioned container.

37. The method according to claim 36, wherein the precursor material is dried by spray drying or freeze-drying.

38. A method for providing a moisture-impermeable container according to claim 1 or 2, The container contains a precursor material containing a fragrance and / or an extract derived from an active plant material, The aforementioned precursor material is dried, A method comprising sealing the aforementioned container.

39. The method according to claim 36, wherein the precursor composition and / or the aerosol generating material comprises an aerosol forming material.

40. The method according to claim 36, further comprising coating the outer surface of the container with an impermeable coating.

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