Aerosol-generating beads, methods for preparing the beads, and compositions and articles comprising the beads

Abstract

The present invention relates to a method for preparing beads for use as an aerosol-generating material in an aerosol delivery system, the method comprising the steps of extruding a mixture to form an extrudate, cutting the extrudate to form beads, and drying the beads at a temperature of 45° C. or less to reduce the moisture content of the beads to about 10% or more by weight. The present invention also relates to an aerosol-generating material comprising at least one bead, and to an article comprising the aerosol-generating material.

Description

[Technical Field]

[0001] The present invention relates to beads for use as an aerosol-forming material in an aerosol delivery system, an aerosol-forming material comprising at least one extruded-dried bead, and a method for preparing an article comprising an aerosol-forming material for use in an aerosol delivery system. [Background technology]

[0002] 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 aerosols that have the taste and texture of authentic tobacco. One problem encountered with such materials is that the methods used to produce them can adversely affect flavor. For example, volatile compounds can evaporate, and the drying process can cause marmolization of the material. A further problem can be that the moisture content of such materials can adversely affect the flavor and flavor profile of the material over time during use. Therefore, there is a need to improve the flavor of aerosol-generating materials. Summary of the Invention

[0003] According to a first aspect of the present invention, there is provided a method for preparing beads for use as an aerosol-generating material in an aerosol delivery system, the method comprising: extruding the mixture to form an extrudate, the mixture comprising plant particles, an aerosol former material, and water; cutting the extrudate to form beads; drying the beads by heating them to a temperature of about 45°C or less to reduce the moisture content of the beads to about 10% or more by weight.

[0004] In some embodiments, the beads are dried to reduce the moisture content to about 13% or more by weight.

[0005] In some embodiments, the beads are dried to reduce the moisture content to about 20% or less by weight.

[0006] In some embodiments, the beads are heated to a temperature of about 35° C. or less.

[0007] In some embodiments, the beads are dried using a heated air dryer or a fluidized bed processor.

[0008] In some embodiments, the beads are dried using a forced stream of heated air that moves the beads.

[0009] In some embodiments, the beads are exposed to a stream of air heated to a temperature of about 30°C to about 45°C.

[0010] In some embodiments, the beads are dried for up to about 10 hours, and optionally for up to about 2 hours.

[0011] In some embodiments, the cut extrudate is spheronized.

[0012] In some embodiments, the mixture further comprises one or more of a binder, a filler, and a flavoring agent.

[0013] According to a second aspect of the present invention, there is provided an aerosol-generating material comprising at least one extruded, dried bead comprising plant particles and an aerosol former material, the bead having a moisture content of about 10% or more by weight.

[0014] In some embodiments, the beads have a diameter of about 0.5 to about 5 mm.

[0015] In some embodiments, the beads have a moisture content of about 13% or greater by weight.

[0016] In some embodiments, the beads have a moisture content of about 20% or less by weight.

[0017] In some embodiments, the beads comprise plant particles in an amount of about 10% to about 80% by weight, and sometimes about 25% to about 80% by weight.

[0018] In some embodiments, the plant particles have a diameter of about 0.5 mm or less, and optionally the plant particles have a diameter of about 0.1 mm or less or about 0.06 mm or less.

[0019] In some embodiments, the beads comprise aerosol former material in an amount of about 1% to about 50% by weight, optionally about 10 to about 30% or about 15 to about 20% by weight.

[0020] In some embodiments, the aerosol former material is selected from the group consisting of glycerin, 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.

[0021] In some embodiments, the beads comprise a binder in an amount of about 0.01% to about 5% by weight, optionally about 0.5 to about 1.5% by weight.

[0022] In some embodiments, the binder is selected from the group consisting of thermoreversible gelling agents such as gelatin, starch, polysaccharides, pectin, alginate, wood pulp, cellulose, and cellulose derivatives such as carboxymethylcellulose.

[0023] In some embodiments, the beads further comprise a filler in an amount of from about 0.01% to about 40% by weight, optionally from about 10 to about 35% by weight, or from about 15 to about 30% by weight.

[0024] In some embodiments, the filler is selected from the group consisting of calcium carbonate, microcrystalline cellulose, wood fiber, carboxymethyl cellulose, titanium dioxide, sodium carbonate, clay, limestone, talc, and gypsum.

[0025] In some embodiments, the beads further comprise a flavoring, optionally in an amount of about 0.01% to about 5% by weight, optionally about 2 to about 4% by weight.

[0026] In some embodiments, the aerosol-generating material further comprises plant material in different forms in addition to the beads.

[0027] According to a third aspect of the present invention there is provided an article for use in an aerosol delivery system comprising an aerosol-forming material according to the second aspect.

[0028] In some embodiments, the article comprises a section comprising an aerosol-generating material that comprises beads, and further comprises one or more sections of reconstituted plant material.

[0029] In some embodiments, the article further comprises a filter at or near the mouth end of the article.

[0030] In some embodiments, the article further comprises a cooling segment disposed between the section of aerosol-forming material and the mouth end of the article.

[0031] In some embodiments, the article has a rod shape and the section of aerosol-forming material is cylindrical.

[0032] In some embodiments, the article comprises a chamber that holds an aerosol-forming material that includes beads.

[0033] In some embodiments, the article comprises a removable cartridge having a housing defining an interior chamber in which beads are retained.

[0034] According to a fourth aspect of the present invention there is provided an aerosol delivery system comprising an aerosol delivery device and an article according to the third aspect, The apparatus includes a heating system configured to heat the aerosol-forming material to generate the aerosol.

[0035] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0036] [Figure 1] FIG. 1 is a cross-sectional view of an example of a consumable product including an aerosol-forming material described herein. [Figure 2] FIG. 2 is a perspective view of the consumable item of FIG. 1. [Figure 3] FIG. 1 illustrates an exemplary rod of aerosol-generating material comprising sections of different aerosol-generating materials. [Figure 4] 10A-10C show further exemplary rods of aerosol-generating material having alternative configurations of sections of different aerosol-generating materials. DETAILED DESCRIPTION OF THE INVENTION

[0037] In a first aspect of the present invention, a method is provided for preparing beads for use as an aerosol-generating material in an aerosol delivery system. These beads comprise plant material. In some embodiments, the beads comprise tobacco and / or other plant material. The plant material may comprise active and / or flavor components present in the aerosol generated by heating the beads.

[0038] An aerosol-forming material is a material that can generate an aerosol when energized, for example, by heating, irradiating, or in any other manner. The aerosol-forming material can be used in an aerosol delivery system, which can be non-combustion-based.

[0039] The present invention addresses some of the most significant shortcomings of conventional tobacco heating products and aerosol delivery systems, namely, providing an aerosol that provides an authentic tobacco taste.

[0040] It is known to produce tobacco beads by extruding tobacco material followed by a drying process. However, conventional processing of such known beads can result in a significant loss of desirable tobacco components that contribute to the organoleptic properties of the aerosol produced when such beads are heated. Specifically, conventionally used drying processes involve heating the beads to temperatures of 50°C or higher to drive off excess moisture. At the same time, heating to these temperatures also drives off flavor and aroma components and volatile and semi-volatile components, such as nicotine, from the tobacco starting material present in the beads prior to the drying process.

[0041] The present invention provides plant-based beads that provide users with an improved, long-lasting taste. In particular, the improved method used to prepare the beads ensures that desirable components are retained within the beads, allowing them to contribute to improved aerosols generated therefrom. Specifically, according to the present invention, the beads are prepared using lower drying temperatures, and less moisture is extracted from the beads as a result of the drying process. The gentler method results in beads with a higher moisture content and a higher content of volatile and semi-volatile plant components than previously seen, which positively contribute to the properties of the aerosols generated when the beads are heated, for example, in an aerosol delivery system.

[0042] The invention described herein takes advantage of the fact that the beads, and aerosol-forming materials including such beads, can contain more flavor components than conventionally produced tobacco beads.

[0043] Compared to tobacco beads produced by conventional methods, beads prepared by the methods of the present invention described herein may provide a more consistent and gradual release of volatile and semi-volatile plant components. Aerosol-forming materials comprising the beads of the present invention may also deliver improved taste to the user over a longer period of time. In some embodiments, the beads have a specific release profile, such that active and / or flavor notes are gradually and consistently released and delivered to the user over time.

[0044] The flavor may be the flavor of the plant material, such as tobacco, contained in the beads and / or the flavor of any additional flavors or ingredients. The inventors have found that the lower drying temperature and higher moisture content of the dried beads together provide this particularly well-delivered flavor, which gives the release profile and flavor advantages described above.

[0045] Another advantage of the present invention is that, in some embodiments, beads and aerosol-generating materials including such beads can deliver two or more flavors, additional flavors, sensations, or actives to a user. In some embodiments, a mixture of flavors, sensations, or actives is delivered to a user. In some embodiments, the profile of flavors, sensations, or actives delivered to a user can change over time.

[0046] In some embodiments, the aerosol-generating material comprises two or more beads, the beads comprising different flavors, botanical materials, or additional substances, such as additional flavors, sensation enhancers, or active substances, as described herein. In some embodiments, the aerosol-generating material comprises beads having different additional substances that can be mixed together to provide a user with a mixture of flavors, sensations, or active substances. The additional flavor is an additional beneficial ingredient delivered to the user in addition to the flavor component of the botanical material in the beads.

[0047] The method of preparing tobacco beads disclosed herein includes extruding a mixture to form an extrudate, the extruded mixture including plant particles, an aerosol former material, a binder, and water.

[0048] In some embodiments, the mixture and the beads comprise the same components. In some embodiments, the mixture, the beads, and the aerosol-forming material comprising at least one bead comprise the same components.

[0049] The mixture that is extruded may be in the form of a slurry, suspension, gel, liquid or solid.

[0050] In some embodiments, the mixture and / or beads include plant particles, aerosol former material, a binder, and water.

[0051] In one preferred embodiment, the plant particles used to form the beads are derived from tobacco. While much of the following discussion specifically refers to tobacco particles and tobacco beads, the present disclosure is intended to relate to materials from other plants as well. In particular, the present invention relates to plant materials that include at least one active substance and / or flavor.

[0052] The plant particles used in the methods and products discussed herein can comprise any form of suitable plant material. In some embodiments, the plant particles comprise ground plant material. In some embodiments, the plant particles comprise tobacco plants. The plant particles can be in the form of a powder or a free-flowing powder.

[0053] In some embodiments, the plant particles are formed from tobacco. For example, the tobacco particles are ground tobacco material. In other embodiments, alternative plant materials can be used in conjunction with or in place of tobacco.

[0054] The tobacco material may be from any type of tobacco and any part of the tobacco plant, including tobacco blades, stems, stalks, veins, scraps, and bits, or a mixture of two or more thereof. Suitable tobacco materials include the following types: Virginia or flue-cured tobacco, Burley tobacco, Oriental tobacco, or a blend of tobacco materials, optionally including those listed herein. 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-treated or un-treated, 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-treated. The tobacco material may be provided in the form of cut rag tobacco. Cut rag tobacco may have, for example, a cut width of at least 15 cuts per inch (approximately 5.9 cuts per cm, which corresponds to a cut width of approximately 1.7 mm). Cut rag tobacco may 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.

[0055] In some embodiments, the plant particles have a diameter of about 5 mm or less, about 4 mm or less, about 3 mm or less, about 2 mm or less, about 1 mm or less, about 0.5 mm or less, about 0.1 mm or less, about 0.08 mm or less, about 0.06 mm or less, or about 0.03 mm or less. In some embodiments, the plant particles have a diameter of about 0.06 mm or less. In some embodiments, the plant particles have a diameter of at least about 0.2 mm, at least about 0.5 mm, at least about 1 mm, or at least about 2 mm.

[0056] The size of the plant particles is preferably small enough to form a mixture suitable for extrusion. The plant particle size may be measured by sieving or by observing the size of the particles by SEM. If necessary, the plant particles or mixture can be treated to ensure that they do not contain particles having a size larger than desired as determined by sieving.

[0057] In some embodiments, the mixture and / or beads contain at least about 10% by weight, at least about 15% by weight, at least about 20% by weight, at least about 25% by weight, at least about 30% by weight, at least about 35% by weight, or at least about 40% by weight of plant particles (calculated on a wet weight basis). Additionally or alternatively, the mixture or beads contain up to about 80% by weight, up to about 70% by weight, up to about 60% by weight, up to about 55% by weight, up to about 50% by weight, up to about 45% by weight, or up to about 40% by weight of plant particles (calculated on a wet weight basis). In some embodiments, the mixture or beads contain between about 20% by weight and about 40% by weight of plant particles (calculated on a wet weight basis). In some embodiments, these plant particles are tobacco particles.

[0058] In some embodiments, the mixture and / or beads include about 1% to about 50% of the aerosol former material, hi some embodiments, the mixture and / or beads include about 5% to about 40%, about 10% to about 30%, or about 15% to about 20% of the aerosol former material.

[0059] The aerosol former material may include one or more components capable of forming an aerosol. In some embodiments, the aerosol former material may include one or more of glycerin, 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 phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0060] In some embodiments, the mixture and / or beads include a binder in an amount of about 0.1% to about 5%. In some embodiments, the mixture and / or beads include a binder in an amount of about 0.1% to about 5%, about 0.5% to about 4.5%, about 0.5% to about 3%, or about 0.5% to about 1.5%. The binder may be selected from the group consisting of a thermoreversible gelling agent such as gelatin, starch, polysaccharides, pectin, alginate, wood pulp, cellulose, and cellulose derivatives such as carboxymethylcellulose, or combinations thereof.

[0061] Extrusion The mixture is extruded to produce extrudates.

[0062] Extrusion can be carried out using one of the major types of extruders: screw, sieve and basket, roll, ram, and pin barrel extruders. This has the advantage that this process combines mixing, conditioning, homogenization, and shaping of the components of the mixture. An additional advantage is that extrusion provides a uniform distribution of the components throughout the extrudate. In embodiments where flavors are added to the mixture, the extrusion process serves to further structurally integrate the flavor into the extrudate and modify the release profile from the final beads.

[0063] The extrudate may be in any suitable form, hi some embodiments, the extrudate is in the form of a strand or rod.

[0064] In some embodiments, the extruded strands are about 0.5 to about 3 mm wide. In some embodiments, the strands are about 1 to about 2 mm wide. The width of the strands may be selected to improve extrusion rate and / or to provide beads of a desired size.

[0065] The extrudate may be cut to form extrudate pieces. In some embodiments, the extrudate is cut as it exits the extruder die or shortly thereafter. In other embodiments, the extrudate strands may be cut in a separate processing step, optionally at a location removed from the extruder.

[0066] In some embodiments, the extruded strands are cut into pieces having lengths of about 0.5 to about 3 mm. In some embodiments, the cut pieces of extrudate have lengths of about 1 to about 2 mm. The length of the pieces into which the extruded strands are cut may be selected to provide beads of a desired size. In some embodiments, the cut pieces of the extruded strands have a length approximately equal to their width.

[0067] Spheroidization In some embodiments, the cut pieces of extrudate can be subjected to additional processing to adjust their size and / or shape, for example to make them more uniform and / or more spherical. In some embodiments, the method for preparing beads includes a spheronization step (also called marmolization or pelletization).

[0068] Spheronization is a process that produces substantially uniformly sized spherical particles, commonly referred to as spheres, spheroids, or pellets. An advantage of spheronization is that the resulting beads are of a substantially consistent size and / or shape. This makes the beads and / or aerosol-generating materials containing the beads easier to handle, pack, and process. Furthermore, this allows a more precise amount of beads to be measured into an article, thereby providing a precise and predictable amount of flavor or other ingredient within the article. Preferably, the particles are spherical or spheroidal. This can be advantageous for packing the article and for providing good airflow through the article and the aerosol-generating device.

[0069] Drying The drying process involves reducing the moisture content of the beads; the purpose of drying is to remove moisture from the formed beads. This can be accomplished using any suitable equipment, including ovens, heaters, hot air, or other devices. Various types of drying equipment are known, and are typically selected based on the desired moisture content of the resulting dried beads and the chemical and physical properties of the beads being dried. In some embodiments of the present invention, the drying equipment uses a flow of heated air to move the beads up and down. In some embodiments, the drying equipment is a fluidized bed processor, such as a Flowcoater Granulator and / or a Granulator VFC 60M. Fluidized bed processors offer the advantage of being able to configure the equipment to provide appropriate drying conditions.

[0070] A preferred drying process or method is one that does not result in significant changes in the morphology, density and size of the beads, meaning that extrusion, cutting and optional spheronization can be carried out to produce dried beads of known desired morphology, density and size.

[0071] In some embodiments, the drying step heats the beads to a temperature of 45° C. or less. In some embodiments, the temperature of the beads is heated to 40° C., 35° C., 30° C., or 25° C. or less during the drying step. In some embodiments, the temperature of the mixture or beads does not exceed 45° C. at any time during the process of preparing the beads.

[0072] The drying step may include exposing the beads to a heated air stream, hi some embodiments, the beads are exposed to an air stream heated to a temperature of about 30°C to about 45°C.

[0073] In some embodiments, the drying time can be up to about 10 hours. The drying time is selected based on the drying temperature, as it is intended to dry the beads to the target moisture content using lower drying temperatures. The batch size and ingredients of the beads can also affect the time required to dry the beads to the target moisture content. In some embodiments, the drying time can be up to about 8 hours, up to about 6 hours, up to about 4 hours, up to about 2 hours, or up to about 1 hour. In some embodiments, the drying time is at least about 30 minutes, at least about 60 minutes, at least about 90 minutes, at least about 120 minutes, at least about 180 minutes, at least about 240 minutes, or at least about 300 minutes. For example, in some embodiments, the beads may be dried at 45°C for 1 hour until a moisture content of 13% is reached. In another example, the beads may be dried at 35°C for 2 hours until a moisture content of 13% is reached. In some embodiments, the beads may be dried to a moisture content ranging from about 5% to about 30%.

[0074] According to the methods described herein, the beads are heated at lower temperatures and for longer than conventional methods, preserving more of the components of the starting material, thereby providing a particularly intense and consistent taste to the end user when the beads are used to generate an aerosol. The gentler drying process can leave a more even distribution of flavor in the beads, which is then delivered to the user during use.

[0075] It is known that the higher the drying temperature, the more volatile compounds are released during processing. Unexpectedly, the present inventors have found that when the beads are dried using a temperature of 45°C or less, the beads have particularly satisfactory flavor and flavor retention. This effect is even more pronounced when the beads are dried using a temperature of 35°C or less.

[0076] Without wishing to be bound by any particular theory, it is believed that when higher drying temperatures are used, volatile compounds located toward the center of the bead are retained, while volatile compounds located toward the outside of the bead may be released and lost during the drying process.In contrast, when the beads are dried at the lower drying temperatures used in the present invention, these volatile compounds are retained and therefore present throughout the bead.This provides the user with a sustained taste delivery over time when the beads are heated to form an aerosol.

[0077] Determining moisture content is important in the tobacco industry because moisture has a significant effect on tobacco materials, their processing characteristics, and the final product itself. The terms "moisture" or "moisture content" are used to refer to the moisture content of a material. Moisture content can be determined by Karl Fischer analysis or gas chromatography-thermal conductivity detection (GC-TCD), as known to those skilled in the art. Karl Fischer titration is a classic method of chemical analysis for reliably determining the amount of water, even trace amounts, in a sample. This method can be easily performed using an automated Karl Fischer titrator. Similarly, the use of GC-TCD is also an established method for reliably determining the moisture content in a sample. Unless otherwise specified, references to moisture content herein refer to the moisture content measured by Karl Fischer.

[0078] The methods disclosed herein include drying the beads to a moisture content of about 0% to about 30% by weight, in some embodiments, the moisture content is reduced to about 20% or more, about 15% or more, about 13% or more, about 6% or more, or to about 0% by weight.

[0079] In some embodiments, the beads are dried to a moisture content of about 20% or less by weight, about 18% or less by weight, or 15% or less by weight.

[0080] Additionally, the dry beads disclosed herein, and optionally prepared using the methods disclosed herein, have a moisture content of about 10% or greater by weight, hi some embodiments, the beads have a moisture content of about 13% or greater by weight, or about 15% or greater by weight.

[0081] In some embodiments, the beads have a moisture content of about 20% by weight or less, about 18% by weight or less, or about 15% by weight or less.

[0082] It is important to dry the beads to an appropriate moisture content. If the moisture content is too low, for example, below 9%, the beads will lose their flavor. If the moisture content is below 6%, flavor components and nicotine may be lost, for example, by evaporation or flash evaporation. The texture of the beads will also change. If the moisture content is too high, the shelf life of the beads may be adversely affected, for example, due to increased microbial growth or an increase in the amount of tobacco-specific nitrosamines (TSNAs) generated over time. Furthermore, if the moisture content is too high, the flavor profile of the beads may be adversely affected. A high moisture content, such as above 20%, may increase the perceived aerosol warmth or "hot puff" sensation, as described herein. Finally, beads with a higher moisture content may also be less suitable for machining.

[0083] Without wishing to be bound by any particular theory, it is believed that the lower drying temperature and higher moisture content of the beads changes the chemical makeup of the beads, resulting in a different chemical makeup that locks in flavor.

[0084] Unexpectedly, the inventors have found that despite the higher moisture content of the beads, the beads are still resistant to microbial growth.This provides the additional advantage of contributing to the long shelf life of the beads.Without wishing to be bound by any particular theory, it is believed that a combination of nicotine content and moisture content of less than 20% inhibits the growth of bacteria and / or mold.

[0085] In another unexpected discovery, the inventors found that users do not notice a "hot puff" when using the beads in an aerosol generating device, despite the higher moisture content of the beads. A "hot puff" is a sensation of evaporated moisture that is generally associated with aerosol-generating materials having a higher moisture content and is generally perceived negatively by users. Without wishing to be bound by any particular theory, it is believed that increasing the surface area and depth or density of the bead matrix results in a more gradual release of moisture, thereby reducing the chance of experiencing a "hot puff."

[0086] This means that the beads can have a higher moisture content without the drawbacks normally associated with aerosol-forming materials having a higher moisture content.

[0087] (Tobacco) beads The beads can be substantially spherical or spheroidal. In some embodiments, the beads have a non-uniform shape. In some embodiments, the size of the tobacco beads ranges from about 1 mm to about 2 mm in one dimension. In some embodiments, the size of the beads ranges from about 1.2 mm to about 1.8 mm, or from about 1.4 mm to about 1.6 mm. The size of the beads can be selected to provide an optimal surface area to volume ratio for controlling aerosol generation and release of volatile components, thereby providing the desired flavor intensity to the user and providing sustained flavor generation over a period of use. Additionally, the particle size can be selected to be suitable for incorporation into the aerosol-generating material in the article.

[0088] In some embodiments, the beads have a shelf life of at least 6 months, at least 8 months, or at least 1 year. The term shelf life means that the flavor is stable over this period and the beads provide the same taste delivery profile after this period. The beads enjoy the advantage of being easy to store and transport.

[0089] A further advantage of the beads and aerosol-generating materials comprising at least one such bead is that the beads are free-flowing, making them easy to add and remove from consumables or to combine with other materials to form aerosol-generating materials.

[0090] In some embodiments, the mixtures and beads include plant particles formed from different plants or different parts of plants, which provide different flavors and / or different actives to the user.

[0091] In some embodiments, the mixtures and beads include tobacco particles formed from different tobacco materials to provide different tastes to the user.

[0092] Aerosol-Generating Materials In another aspect of the present invention, an aerosol-generating material is provided, comprising at least one extruded-dried bead comprising plant particles, a binder, and an aerosol former material, the bead having a moisture content of about 10% by weight or greater.

[0093] The aerosol-generating material may be, for example, in the form of a solid, liquid, or gel. The aerosol-generating material may or may not include an active agent and / or flavoring agent disclosed herein. In some embodiments, the aerosol-generating material may comprise an "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material that can retain some fluid, such as a liquid, within the amorphous solid. In some embodiments, the aerosol-generating material may comprise, for example, from about 50%, 60%, or 70% by weight of an amorphous solid to about 90% or about 95% by weight of an amorphous solid.

[0094] The aerosol-generating material may further include one or more active agents and / or additional flavors, one or more aerosol former materials, and optionally one or more other functional materials, as described herein.

[0095] In some embodiments, the aerosol-generating material may include a binder or gel. This has the advantage that the beads may bind together to form clumps. This changes the surface area to volume ratio of the aerosol-generating material, thus affecting its taste profile. Another advantage is that the aerosol-generating materials do not mix when two or more aerosol-generating materials are incorporated into the article.

[0096] In some embodiments, the aerosol-generating material has a substantially cylindrical shape or a substantially circular cross-section. In some embodiments, the aerosol-generating material has a cylindrical shape or a circular cross-section. In some embodiments, one or more sections of the aerosol-generating material have a substantially cylindrical shape or a substantially circular cross-section. This has the advantage of being a shape that is easy to handle and use.

[0097] In some embodiments, the aerosol-generating material includes two or more beads, at least some of which have different compositions. For example, the aerosol-generating material may include at least one first bead including a first additional flavor or botanical material and at least one second bead including a second additional flavor or botanical material. This embodiment offers the advantage that beads having different additional flavors can be combined in different proportions to provide a distinct or unique flavor profile to the user.

[0098] Alternatively or additionally, the beads may contain different aerosol-forming materials or binders, or different amounts of these components. Alternatively or additionally, the beads may have different densities, different shapes, and / or different sizes. Thus, the composition of the aerosol-generating material can be selected to provide a specific flavor to the user. In some embodiments, the aerosol-generating material including beads may deliver flavors at different rates. This embodiment has the advantage of providing the user with different flavors over time, providing a complex flavor profile.

[0099] additional flavor In some embodiments, the mixture, beads, and / or aerosol-forming material further comprises at least one additional flavor described herein, hi some embodiments, the substance to be delivered comprises an additional flavor in addition to the flavors and tastes provided by the plant material or other components in the beads.

[0100] As discussed herein, the beads produced by the methods of the present invention provide a particularly enhanced and persistent flavor profile of the added flavor.

[0101] In some embodiments, the mixture, beads and / or aerosol-forming material have no added flavor.

[0102] As used herein, the terms "flavor" and "flavoring agent" refer to materials that may be used, where local regulations permit, to create a desired taste, aroma, or other somatic sensation in products intended for adult consumers.

[0103] In some embodiments, the additional flavor is a naturally occurring flavor material, a botanical, an extract of a botanical, a synthetically derived material, or a combination thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed, cinnamon, turmeric, Indian spice, Asian spice, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, etc.). Go, clementine, lemon, lime, tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, eggplant, betel nut, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, kimchi Challaway, 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 leaf, yerba mate, orange peel, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, oak sucralose, valerian, pimento, mace, damiane, marjoram, olive, lemon balm, lemon basil, chives, Calvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and charcoal, chlorophyll, minerals, plant substances,The compositions may also contain other additives such as ointments, emollients, or breath fresheners. They may be imitation, synthetic, or natural ingredients, or blends thereof. They may be in any suitable form, for example, a liquid such as an oil, a solid such as a powder, or a gas.

[0104] In some embodiments, the flavor comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavor comprises cucumber, blueberry, citrus, and / or red berry flavor components. In some embodiments, the flavor comprises eugenol. In some embodiments, the flavor comprises flavor components extracted from tobacco. In some embodiments, the flavor comprises flavor components extracted from cannabis.

[0105] In some embodiments, the flavor may include a sensation eliciting agent intended to achieve somatic sensations typically chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to, or instead of, the aroma or taste nerves, and these may include agents that produce heating, cooling, tingling, and numbing effects. 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.

[0106] In some embodiments, the beads may contain one flavor. In some embodiments, the beads may contain two or more flavors, for example, to deliver two or more flavors or flavor combinations. This embodiment enjoys the advantage that the flavor is evenly distributed throughout the beads. The beads retain the flavor during use, providing a persistent flavor profile.

[0107] Additional ingredients In some embodiments, the mixture and / or the beads and / or the aerosol-forming material include additional components.

[0108] In some embodiments, the mixture and / or beads and / or aerosol-forming 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.

[0109] In some embodiments, the mixture and / or beads and / or aerosol-forming material includes 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 includes less than 60% by weight of filler, 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. The filler provides the advantage of providing beads with a desired density and size for use.

[0110] When present, the filler may comprise one or more inorganic filler materials such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents such as molecular sieves. The filler may also comprise one or more organic filler materials such as wood pulp, hemp fiber, cellulose, and cellulose derivatives. In some embodiments, the filler is selected from the group consisting of calcium carbonate, carboxymethylcellulose, titanium dioxide, sodium carbonate, clay, limestone, talc, and gypsum.

[0111] In some embodiments, the mixture and / or beads and / or aerosol-forming material contain one or more active agents, which may be obtained from an extract or may be added. In some embodiments, an extract from flavor-containing or active-containing plant material contains the active agents.

[0112] 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, 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 plant material.

[0113] In some embodiments, the active substance comprises added nicotine. In some embodiments, the mixture and / or beads and / or aerosol-forming material do not comprise added nicotine.

[0114] In some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0115] In some embodiments, the mixture and / or beads and / or aerosol-forming material may include extracts from other plant sources in addition to or in place of tobacco extract.

[0116] 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. An extract may comprise or be derived from botanical matter in the form of a liquid, gas, solid, powder, dust, 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 leaf, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, The mint may be selected from the following mint varieties: lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiana, 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 acuta (spider mint), Mentha cv (spider mint), Egyptian mint, peppermint, eau de cologne mint, candy mint, curly mint, Kentucky kernel mint, horse mint, pineapple mint, pennyroyal mint, green mentha, and apple mint.

[0117] 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.

[0118] 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.

[0119] In some embodiments, the mixture and / or beads and / or aerosol-generating material comprises one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiolic 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).

[0120] In some embodiments, the flavor may include a sensation eliciting agent intended to achieve somatic sensations typically chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to, or instead of, the aroma or taste nerves, and these may include agents that produce heating, cooling, tingling, and numbing effects. 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.

[0121] Goods In another aspect of the invention, an article for use in an aerosol delivery system is provided that includes an aerosol-forming material of the invention.

[0122] The article includes or consists of at least one aerosol-generating material, some or all of which is intended to be consumed during use by a user. The article may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol-generating area, a housing, a packaging material, a mouthpiece, a filter, and / or an aerosol modifier. The article 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.

[0123] In some cases, the article has a rod shape. In some embodiments, the article further comprises a packaging material surrounding the rod. As used herein, the term "rod" generally refers to an elongated body that may be of any suitable shape for use in an aerosol generating assembly. In some cases, the rod is substantially cylindrical.

[0124] Articles that include aerosol-forming materials can advantageously be biodegradable or include biodegradable components. In such embodiments, the articles can also include biodegradable packaging.

[0125] In some embodiments, the article may be filled with aerosol-forming material, such that the aerosol-forming material fills the volume of the article and the beads cannot significantly move or rotate, which has the advantage that the article is easy to handle.

[0126] In some embodiments, the article includes two or more aerosol-generating materials. For example, one section of the article may include a first aerosol-generating material (e.g., including beads with a first additional flavor) and a different section of the article may include a second (different) aerosol-generating material (e.g., including beads with a second additional flavor).

[0127] In some embodiments, an article includes at least one aerosol-generating material comprising at least one extruded-dried bead described herein and at least one other form of aerosol-generating material, such as a different form of plant material. In some embodiments, the article can include reconstituted plant material in addition to the aerosol-generating material comprising at least one extruded-dried bead.

[0128] In some embodiments, an article includes at least one aerosol-forming material comprising at least one extruded dried tobacco bead as described herein and at least one other form of aerosol-forming material, such as a different form of tobacco. In some embodiments, the article can include reconstituted tobacco and an aerosol-forming material comprising at least one extruded dried tobacco bead. The aerosol-forming material and the reconstituted tobacco can be in any proportion.

[0129] In embodiments in which an article includes two or more aerosol-generating materials, the aerosol-generating materials may be homogeneously mixed. Alternatively, in some embodiments, the article may include different aerosol-generating materials in different sections. A section refers to a portion of the article that includes an aerosol-generating material. The sections may have different lengths or sizes or the same size or length.

[0130] Thus, the articles described herein enjoy the advantage of being adaptable, and many different configurations and arrangements are envisioned that can be selected to provide the best taste profile for the user. Furthermore, the user may be able to configure the article to include a desired ratio of aerosol-forming material to other forms of plant material, such as tobacco. The user may also be able to adapt the composition, ratios, and flavors of the sections to provide a personalized taste profile.

[0131] In some embodiments, the article may include at least two flavors. The flavors may be "layered" and delivered to the user over a period of time. In some embodiments, beads containing different flavors may be layered within the article. For example, an inner layer of beads containing a first flavor may be surrounded by an outer layer of beads containing a second flavor. This provides the advantage that differential exposure to heat results in a dynamic flavor transition between the layers.

[0132] Embodiments in which the article includes at least one other form of plant material in addition to beads have the advantage of limiting the movement of the beads, which also provides the additional advantage of making the article easier to handle. For example, the plant material may form a plug at least on one end of the article, which advantageously prevents movement or loss of the beads.

[0133] In some embodiments, the article further comprises a filter at or near the mouth end of the article, which provides the benefit of filtering the generated aerosol and may also act as a plug to prevent migration or loss of beads.

[0134] In some embodiments, the article further comprises a cooling segment disposed between the section of aerosol-forming material and the mouth end of the article.

[0135] In some embodiments, the article further comprises a plug that at least partially closes at least one end of the article and prevents loss of aerosol-forming material through said end. The plug may comprise, for example, a gel, a metal (such as aluminum), or tobacco.

[0136] In some embodiments, the article includes a cartridge in which a housing defines an internal chamber in which beads can be held. The housing has an opening through which the beads can be introduced into the internal chamber. The housing of this embodiment can further include a cover or lid for closing the opening, preventing loss of the contents of the internal chamber through the opening. In some embodiments, the article can further include a means for facilitating transfer of the beads to the internal chamber. Such a means can be, for example, a narrow sleeve, a pull top, a sliding opening, or a funnel integrated into the housing to aid in filling the article.

[0137] Embodiments in which the article includes a cartridge that includes a housing for holding the beads enjoy the advantage that the article is refillable and therefore does not need to be disposed of after a single use, which in turn has environmental benefits that can be further enhanced if the beads and / or the housing are biodegradable.

[0138] A further advantage of refillable cartridges is that they allow users to control their experience, for example, by adding beads containing specific types of tobacco or flavors (e.g., including at least one additional flavor) to provide customized products and aerosols. This embodiment enjoys the advantage of providing users with personalized flavors. Furthermore, the preferences delivered can be multi-layered and complex in taste and sensation.

[0139] 1 and 2, there is shown a partial cutaway cross-sectional view and a perspective view of an example of an article or consumable 101. The article 101 is adapted for use with an apparatus having a power source and a heater. The article 101 in this embodiment is particularly suited for use with the apparatus 1 shown in FIG. 5, described below. During use, the article 101 can be removably inserted into the apparatus shown in FIG. 5 at an insertion point 20 in the apparatus 1.

[0140] The example article 101 is in the form of a substantially cylindrical rod that includes a body of an aerosol-forming composition 103 and a filter assembly 105 in the form of a rod. The aerosol-forming composition includes the aerosol-forming materials described herein.

[0141] The filter assembly 105 in the illustrated embodiment includes three segments: a cooling segment 107, a filter segment 109, and a mouth end segment 111. The article 101 has a first end 113, also known as the mouth end or proximal end, and a second end 115, also known as the distal end. The body of the aerosol-forming composition 103 is disposed toward the distal end 115 of the article 101. In one example, the cooling segment 107 is disposed adjacent to the body of the aerosol-forming composition 103 between the body of the aerosol-forming composition 103 and the filter segment 109, such that the cooling segment 107 is in an abutting relationship with the aerosol-forming composition 103 and the filter segment 109. In other examples, there may be a separation between the body of the aerosol-forming composition 103 and the cooling segment 107 and between the body of the aerosol-forming composition 103 and the filter segment 109. The filter segment 109 is disposed between the cooling segment 107 and the mouth end segment 111. Mouth end segment 111 is disposed adjacent filter segment 109 toward proximal end 113 of article 101. In one example, filter segment 109 is in an abutting relationship with mouth end segment 111. In one embodiment, the overall length of filter assembly 105 is between 37 mm and 45 mm, and more preferably, the overall length of filter assembly 105 is 41 mm.

[0142] In one example, the rod of aerosol-forming composition 103 is between 34 mm and 50 mm in length, suitably between 38 mm and 46 mm in length, suitably 42 mm in length.

[0143] In one example, the overall length of the article 101 is between 71 mm and 95 mm, suitably between 79 mm and 87 mm, suitably 83 mm.

[0144] The axial end of the body of aerosol-forming composition 103 is visible at distal end 115 of article 101. However, in other embodiments, distal end 115 of article 101 may include an end member (not shown) that covers the axial end of the body of aerosol-forming composition 103.

[0145] The body of aerosol-forming composition 103 is joined to filter assembly 105 by an annular beveled paper (not shown) that surrounds filter assembly 105, generally around the circumference of filter assembly 105, and extends partially along the length of the body of aerosol-forming composition 103. In one example, the beveled paper is made from 58 GSM standard beveled paper. In one example, the beveled paper has a length of 42 mm to 50 mm, suitably 46 mm.

[0146] In one example, cooling segment 107 is an annular tube that is disposed about the cooling segment and defines a void therein. The void provides a chamber for the flow of heated volatile components generated from the body of aerosol-forming composition 103. Cooling segment 107 is hollow to provide a chamber for aerosol accumulation, yet is rigid enough to withstand axial compressive forces and bending moments that may occur during manufacturing and use of article 101 during insertion into apparatus 51. In one example, the wall thickness of cooling segment 107 is approximately 0.29 mm.

[0147] The cooling segment 107 provides a physical displacement between the aerosol-forming composition 103 and the filter segment 109. The physical displacement provided by the cooling segment 107 provides a thermal gradient across the length of the cooling segment 107. In one example, the cooling segment 107 is configured to provide a temperature difference of at least 40° C. between the heated volatile components entering the first end of the cooling segment 107 and the heated volatile components exiting the second end of the cooling segment 107. In one example, the cooling segment 107 is configured to provide a temperature difference of at least 60° C. between the heated volatile components entering the first end of the cooling segment 107 and the heated volatile components exiting the second end of the cooling segment 107. This temperature difference across the length of the cooling segment 107 protects the temperature-sensitive filter segment 109 from the high temperature of the aerosol-forming composition 103 when heated by the device 51. If no physical displacement is provided between the filter segment 109 and the body of the aerosol-generating composition 103 and the heating element of the device 51, the temperature-sensitive filter segment 109 may be damaged during use and therefore will not effectively perform its required function.

[0148] In one example, the length of the cooling segment 107 is at least 15 mm. In one example, the length of the cooling segment 107 is between 20 mm and 30 mm, more particularly between 23 mm and 27 mm, even more particularly between 25 mm and 27 mm, suitably 25 mm.

[0149] The cooling segment 107 is made from paper, meaning that it is constructed of a material that does not produce compounds of concern, such as toxic compounds, when used adjacent to the heater of the apparatus 51. In one example, the cooling segment 107 is fabricated from a spirally wound paper tube that provides a hollow interior chamber but maintains mechanical rigidity. The spirally wound paper tube can meet the stringent dimensional accuracy requirements of high speed manufacturing processes for tube length, outer diameter, roundness, and straightness.

[0150] In another example, cooling segment 107 is a recess created from a rigid plug wrap or beveled paper that is manufactured to be sufficiently rigid to withstand axial compressive forces and bending moments that may occur during manufacturing and use of article 101 during insertion into apparatus 51.

[0151] The filter segment 109 may be formed of any filter material sufficient to remove one or more volatile compounds from the heated volatile components from the aerosol-generating material. In one example, the filter segment 109 is made of a monoacetate material, such as cellulose acetate. The filter segment 109 provides cooling and reduced irritation from the heated volatile components without depleting the amount of the heated volatile components to an unsatisfactory level for the user.

[0152] In some embodiments, a capsule (not shown) can be provided within filter segment 109. It may be substantially centrally located within filter segment 109 across the diameter and along the length of filter segment 109. In other cases, it may be offset in one or more dimensions. The capsule may optionally contain a volatile component, such as a flavoring agent or an aerosol-forming agent composition, if present.

[0153] The density of the cellulose acetate tow material of the filter segment 109 controls the pressure drop across the filter segment 109, which in turn controls the retraction resistance of the article 101. Therefore, the selection of material for the filter segment 109 is important in controlling the retraction resistance of the article 101. Additionally, the filter segment performs a filtration function within the article 101.

[0154] In one example, the filter segment 109 is made from 8Y15 grade filter tow material, thereby providing a filtering effect to the heated volatile material while also reducing the size of condensed aerosol droplets resulting from the heated volatile material.

[0155] The presence of filter segment 109 provides an insulating effect by providing additional cooling to the heated volatile components exiting cooling segment 107. This additional cooling effect reduces the contact temperature of the user's lips on the surface of filter segment 109.

[0156] In one example, the length of the filter segment 109 is between 6 mm and 10 mm, suitably 8 mm.

[0157] The mouth end segment 111 is an annular tube that is disposed about the mouth end segment 111 and defines a void therein. The void provides a chamber for the heated volatile components that flow from the filter segment 109. The mouth end segment 111 is hollow to provide a chamber for aerosol accumulation, yet is rigid enough to withstand axial compressive forces and bending moments that may occur during manufacture and use when the article is inserted into the device 51. In one example, the wall thickness of the mouth end segment 111 is about 0.29 mm. In one example, the length of the mouth end segment 111 is between 6 mm and 10 mm, suitably 8 mm.

[0158] The mouth end segment 111 may be manufactured from a spirally wound paper tube that provides a hollow interior chamber yet maintains critical mechanical rigidity. A spirally wound paper tube can meet the stringent dimensional accuracy requirements of high speed manufacturing processes for tube length, outer diameter, roundness, and straightness.

[0159] Mouth end segment 111 serves the function of preventing liquid condensate that accumulates at the outlet of filter segment 109 from coming into direct contact with the user.

[0160] It should be appreciated that in one example, the mouth end segment 111 and the cooling segment 107 may be formed from a single tube, with the filter segment 109 positioned within the tube separating the mouth end segment 111 and the cooling segment 107.

[0161] 3 and 4, schematic diagrams of exemplary bodies of aerosol-forming compositions that may be included in an article such as the article shown in FIG. 1 are shown.

[0162] 3 shows an exemplary body of an aerosol-forming composition 203 comprising three distinct sections. Plugs, segments, or sections comprising reconstituted tobacco 201 are disposed at either end of the illustrated body 203. Plugs, segments, or sections comprising aerosol-forming material, including extruded dried tobacco beads produced according to the method 202 of the present invention, are disposed between the sections of reconstituted tobacco 201. In this embodiment, the sections comprising reconstituted material 201 prevent excessive movement of the aerosol-forming material 202 and retain it within the article.

[0163] 4 shows an exemplary body of aerosol-generating composition 203 containing five sections of aerosol-generating material. Plugs, segments, or sections containing reconstituted tobacco 201 are alternated with plugs, segments, or sections containing aerosol-generating material including extruded-cured tobacco beads produced according to method 202 of the present invention. The sections containing reconstituted tobacco 201 are positioned at either end of the illustrated body 203 to prevent the aerosol-generating material including the extruded-cured tobacco beads from falling out of the body of aerosol-generating composition 203. Sections 202 may contain beads containing one or more flavors. For example, the beads in both sections 202 may contain the same flavor or different flavors.

[0164] Aerosol Delivery System In another aspect of the invention, an aerosol delivery system can include an aerosol delivery device and an article. In such embodiments, the device includes a heating system configured to heat an aerosol-forming material to generate an aerosol.

[0165] In some embodiments, the aerosol delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0166] According to the present disclosure, a "non-combustion" aerosol delivery system is one in which the constituent aerosol-generating materials (or components of those materials) of the aerosol delivery system are not combusted or burned to facilitate delivery of at least one substance to a user.

[0167] In some embodiments, the non-combustion aerosol delivery system is a vaporizer or an electronic cigarette, also known as an electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0168] 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.

[0169] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates aerosol using a combination of aerosol-forming materials, one or more of which may be heated. In some embodiments, the hybrid system comprises a liquid or gel aerosol-forming material and a solid aerosol-forming material. The solid aerosol-forming material may include, for example, tobacco or a non-tobacco product.

[0170] Typically, a non-combustion aerosol delivery system may include a non-combustion aerosol delivery device and an item or consumable for use with the non-combustion aerosol delivery device.

[0171] In some embodiments, the present disclosure relates to articles that include aerosol-forming materials and are configured for use with non-combustion aerosol delivery devices. These articles may be referred to as consumables throughout this disclosure.

[0172] In some embodiments, a non-combustion aerosol delivery system, such as a non-combustion aerosol delivery device, can include a power source and a controller. The power source can be, for example, an electrical power source or a heat-generating power source. In some embodiments, the heat-generating power source includes a carbon substrate that can be energized to deliver power in the form of heat to an aerosol-generating material or a heat-transfer material proximate the heat-generating power source.

[0173] In some embodiments, the non-combustion aerosol delivery system may include an area for receiving a consumable, an aerosol generator, an aerosol-generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0174] In some embodiments, consumables for use with non-combustion aerosol delivery devices may include an aerosol-generating material, an aerosol-generating material storage region, an aerosol-generating material transfer component, an aerosol generator, an aerosol-generating region, a housing, a packaging material, a filter, a mouthpiece, and / or an aerosol modifier.

[0175] example Table 1 below details some examples of articles according to the present invention, each of which includes at least one section containing tobacco beads as described herein.

[0176] [Table 1]

[0177] In some embodiments of these examples, the amount of beads or reconstituted tobacco in the mouth-end section may be about 25 mg ± 2.5 mg.

[0178] In some embodiments of these examples, the amount of beads or reconstituted tobacco in the distal end section may be about 25 mg ± 2.5 mg.

[0179] In some embodiments of these examples, the amount of beads in the middle section may be about 500 mg ± 50 mg. In other embodiments of these examples, the amount of beads in the middle section may be about 250 mg ± 25 mg. In other embodiments of these examples, the amount of reconstituted tobacco in the middle section may be about 20 mg ± 5 mg.

[0180] These embodiments may be combined to form suitable articles.

[0181] Table 2 lists the composition of the mixture extruded to form the beads, according to an illustrative example. Component amounts are provided on a wet weight basis.

[0182] [Table 2]

[0183] Specific examples of the different components listed in Table 2 include: ground plant material comprising or consisting of ground tobacco or any one or more of the other plant materials disclosed herein; a filler material comprising or consisting of calcium carbonate; an aerosol former material comprising or consisting of glycerol, or any one or more of the aerosol former materials disclosed herein; a flavoring comprising or consisting of menthol, or any one or more of the flavorings disclosed herein, and A binder comprising or consisting of carboxymethylcellulose (CMC), or any one or more of the binders disclosed herein.

[0184] The various embodiments described herein are presented solely 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 construed as limitations on the scope of the invention as defined by the claims or limitations on the equivalents of the claims, and it should be understood that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the present invention may suitably comprise, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. Furthermore, the present disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. 1. A method for preparing beads for use as an aerosol-generating material in an aerosol delivery system, the method comprising: extruding the mixture to form an extrudate, the mixture comprising plant particles, an aerosol former material, and water; cutting the extrudate to form beads; drying the beads by heating the beads to a temperature of about 45°C or less to reduce the moisture content of the beads to about 10% or more by weight; A method comprising:

2. 10. The method of claim 1, wherein the beads are dried to reduce the moisture content to about 13% or more by weight.

3. 3. The method of claim 1 or 2, wherein the beads are dried to reduce the moisture content to about 20% or less by weight.

4. The method of any one of claims 1 to 3, wherein the beads are heated to a temperature of about 35°C or less.

5. The method of any one of claims 1 to 4, wherein the beads are dried using a heated air dryer or a fluidized bed processor.

6. 6. The method of any one of claims 1 to 5, wherein the beads are dried using a forced heated air stream that moves the beads.

7. The method of any one of claims 1 to 6, wherein the beads are exposed to a stream of air heated to a temperature of about 30°C to about 45°C.

8. The method of any one of claims 1 to 7, wherein the beads are dried for up to about 10 hours, optionally up to about 2 hours.

9. A method according to any one of claims 1 to 7, wherein the cut extrudate is spheronized.

10. The method of any one of claims 1 to 9, wherein the mixture further comprises one or more of a binder, a filler, and a flavoring agent.

11. An aerosol-generating material comprising at least one extruded-dried bead comprising plant particles and an aerosol former material, the bead having a moisture content of about 10% by weight or greater.

12. 12. The aerosol-forming material of claim 11, wherein the beads have a diameter of about 0.5 to about 5 mm.

13. 13. The aerosol-forming material of claim 11 or 12, wherein the beads have a moisture content of about 13% or more by weight.

14. 14. The aerosol-forming material of claim 11, wherein the beads have a moisture content of about 20% or less by weight.

15. 15. The aerosol-forming material of any one of claims 11 to 14, wherein the beads comprise the plant particles in an amount of from about 10 to about 80% by weight, optionally from about 25 to about 80% by weight.

16. 16. The aerosol-forming material of any one of claims 11 to 15, wherein the plant particles have a diameter of about 0.5 mm or less, and optionally the plant particles have a diameter of about 0.1 mm or less or about 0.06 mm or less.

17. 17. The aerosol-forming material of any one of claims 11 to 16, wherein the beads comprise the aerosol former material in an amount of from about 1% to about 50% by weight, optionally from about 10 to about 30% or from about 15 to about 20% by weight.

18. 18. The aerosol-generating material of any one of claims 11 to 17, wherein the aerosol-generating material is selected from the group consisting of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

19. 19. The aerosol-forming material of any one of claims 11 to 18, wherein the beads comprise a binder in an amount of from about 0.01% to about 5% by weight, optionally from about 0.5 to about 1.5% by weight.

20. 20. The aerosol-forming material of claim 19, wherein the binder is selected from the group consisting of thermoreversible gelling agents such as gelatin, starch, polysaccharides, pectin, alginate, wood pulp, cellulose, and cellulose derivatives such as carboxymethylcellulose.

21. 21. The aerosol-forming material of any one of claims 11 to 20, wherein the beads further comprise a filler in an amount of from about 0.01% to about 40% by weight, optionally from about 10 to about 35% by weight, or from about 15 to about 30% by weight.

22. 22. The aerosol-forming material of claim 21, wherein the filler is selected from the group consisting of calcium carbonate, microcrystalline cellulose, wood fiber, carboxymethyl cellulose, titanium dioxide, sodium carbonate, clay, limestone, talc, and gypsum.

23. 23. The aerosol-forming material of any one of claims 11 to 22, wherein the beads further comprise a flavoring, optionally in an amount of from about 0.01% to about 5% by weight, optionally from about 2% to about 4% by weight.

24. 24. The aerosol-forming material of any one of claims 11 to 23, further comprising, in addition to the beads, plant material in different forms.

25. An article for use in an aerosol delivery system comprising the aerosol-forming material of any one of claims 11 to 24.

26. 26. The article of claim 25, wherein the article comprises a section comprising the aerosol-forming material including the beads, and further comprises one or more sections of reconstituted plant material.

27. 27. The article of claim 25 or 26, wherein the article further comprises a filter at or near the mouth end of the article.

28. 28. The article of any one of claims 25 to 27, wherein the article further comprises a cooling segment disposed between the section of aerosol-forming material and a mouth end of the article.

29. The article of any one of claims 25 to 28, wherein the article has a rod shape and the section of aerosol-forming material is cylindrical.

30. 30. The article of any one of claims 25 to 29, comprising a chamber for holding the aerosol-forming material including the beads.

31. 31. The article of claim 30, wherein the article comprises a removable cartridge having a housing defining an interior chamber in which the beads are retained.

32. An aerosol delivery system comprising an aerosol delivery device and an article according to any one of claims 25 to 31, The aerosol delivery system, wherein the apparatus comprises a heating system configured to heat the aerosol-forming material to generate an aerosol.

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