Dry aerosol-generating material and use thereof

Abstract

The present invention relates to a dry aerosol-generating material, a method of manufacturing a dry aerosol-generating material, and uses thereof.SOLUTION: The dry aerosol-generating material may be used directly as an aerosol-generating material and / or treated with water to provide a conventional aerosol-generating material. The aerosol generating material may be used in combustion-based or non-combustion-based aerosol provision systems.SELECTED DRAWING: Figure 1

Description

Field

[0001] The present invention relates to dry aerosol-forming materials, methods of making dry aerosol-forming materials, and uses thereof.

[0002] Aerosol-generating materials for use in combustion or non-combustion aerosol delivery systems can contain a variety of different actives and / or fragrances, with users selecting the aerosol-generating material that provides the desired user experience. Disadvantages associated with such aerosol-generating materials can include, for example, a lower percentage of components released over time during normal use of the product and after storage of the aerosol-generating material, as well as a shorter shelf life. Therefore, there is a need to improve the shelf life of such aerosol-generating materials.

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

[0004] In some embodiments, the aerosol-forming material is glycerol.

[0005] In some embodiments, the precursor material further comprises at least one excipient.

[0006] In some embodiments, the excipient is one or more selected from the group consisting of mannitol, sucrose, trehalose, lactose, sorbitol, raffinose, maltose, dextran 10, dextran 70, dextran 90, maltodextrin, gelatin, agar, cyclodextrin, PEG 2000-6000, and polyvinylpyrrolidone (PVP)(10k).

[0007] In some embodiments, the precursor material comprises from about 10 to about 95% by weight of an extract derived from a perfume-containing or active-containing plant material.

[0008] In some embodiments, the precursor material comprises from about 1 to about 36 wt % aerosol-forming material.

[0009] In some embodiments, the precursor material comprises from about 0 to about 40% by weight of excipients.

[0010] In some embodiments, the dry aerosol-forming material comprises from about 99 to about 45% by weight of a dry extract derived from flavor-containing or active-containing plant material.

[0011] In some embodiments, the dry aerosol-forming material comprises from about 1 to about 34% by weight of the aerosol-forming material.

[0012] In some embodiments, the dry aerosol-forming material comprises from about 0 to about 25% by weight of excipients.

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

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

[0015] In some embodiments, the dry aerosol-forming material comprises from about 40 to about 99% by weight tobacco solids.

[0016] In some embodiments, the dry aerosol-forming material is in the form of granules, hi some embodiments, the granules have a particle size of up to about 3 mm.

[0017] In some embodiments, the dry aerosol-forming material has a moisture content of about 5% or less.

[0018] In some embodiments, the dry aerosol-forming material is for use in an aerosol delivery system.

[0019] According to a second aspect of the present invention, there is provided a non-combustion aerosol delivery system comprising a dry aerosol-forming material according to the first aspect.

[0020] According to a third aspect of the present invention, there is provided a method of providing a dry aerosol-forming material, the method comprising spray drying or freeze drying a precursor material comprising an extract derived from perfume-containing and / or active-substance-containing plant material and an aerosol-forming material.

[0021] In some embodiments, the dry aerosol-forming material according to the first aspect is contacted with water.

[0022] In some embodiments, contacting the dry aerosol-forming material with water comprises exposing the dry aerosol-forming material to a humid environment.

[0023] In some embodiments, the aerosol-forming material is provided in the form of a solid, liquid, or gel aerosol-forming material.

[0024] In some embodiments, the solid amorphous material is formed from a dry aerosol-forming material.

[0025] 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]

[0026] [Figure 1] 1 is a side cross-sectional view of a first embodiment of a consumable comprising a dry aerosol-forming material. [Figure 2] 2 is a perspective view of a non-combustion aerosol delivery device for generating aerosol from the consumable aerosol-generating material shown in FIG. 1. Detailed Description

[0027] The present invention relates to a dried or dehydrated aerosol-forming material. The dried aerosol-forming material may be used directly as an aerosol-forming material and / or it may be treated with water to provide a rehydrated aerosol-forming material having a more conventional water content.

[0028] The aerosol-forming materials may be used in combustion or non-combustion aerosol delivery systems, or in aerosol-free delivery systems.

[0029] An aerosol-generating material is a material capable of generating an aerosol when energized, for example, by heating, irradiation, or any other method. The aerosol-generating material may be, for example, in the form of a solid, liquid, or gel, and may or may not contain active substances and / or flavorings. The aerosol-generating material may be provided in a dehydrated or hydrated form. 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, e.g., a liquid, within it. In some embodiments, the aerosol-generating material may comprise, for example, about 50 wt%, 60 wt%, or 70 wt% amorphous solid to about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

[0030] The aerosol-forming material may include one or more active agents and / or fragrances, optionally one or more aerosol-forming materials, and optionally one or more other functional materials.

[0031] Combustion and non-combustion aerosol-generating devices, including hybrid devices, may contain aerosol-generating materials, which may include tobacco materials or tobacco extracts, used to provide users with an aerosol having the taste and texture of authentic tobacco. One problem encountered with such devices is that the flavors, volatile compounds, and nicotine content of the aerosol-generating materials decrease with storage, especially toward the end of the material's lifespan. This is because more volatile components, including nicotine and many flavors and aromas, are easily released from the surface of the tobacco material. In addition, the aerosol-generating materials gradually become wet with water, negatively affecting the release of active substances such as nicotine and flavors. Therefore, there is a need to improve the shelf life of aerosol-generating materials.

[0032] The present invention benefits from dry aerosol-generating materials that have an increased shelf life and can be easily transported and stored. Aerosol-generating materials produced using conventional methods and procedures generally need to be used within one to three days of production. The dry aerosol-generating materials described herein are stable over a wide range of temperatures and humidities, have an increased shelf life, and are therefore easy to store and transport. In some embodiments, the dry aerosol-generating materials can be stored at temperatures ranging from 0 to 35°C. In some embodiments, the dry aerosol-generating materials can be stored at a relative humidity of up to about 30%.

[0033] A further advantage of the dry aerosol-forming materials is that they can be used directly as a solid substrate in hybrid systems or tobacco heating products (THPs), making the invention versatile enough for use in a wide range of products without the need for further processing.

[0034] The dry aerosol-forming material comprises a spray-dried or freeze-dried precursor material comprising an extract derived from a perfume-containing and / or active-containing plant material and an aerosol-forming material.

[0035] precursor material In some embodiments, the precursor material has a water content of at least 20% v / v and comprises the components described herein.

[0036] The water content of the aerosol-forming materials described herein can vary according to, for example, the temperature, pressure, and humidity conditions the composition is maintained in. Water content can be determined by Karl-Fisher analysis or by gas chromatography-thermal conductivity detection (GC-TCD), as known to those skilled in the art.

[0037] The precursor material may be in the form of a slurry, suspension, gel, liquid, or solid, although in some embodiments, the precursor material is in the form of a suspension or liquid, which may be preferred. The water content of the precursor material may be at least about 20 wt%, at least about 30 wt%, at least about 40 wt%, at least about 50 wt%, at least about 60 wt%, at least about 70 wt%, at least about 80 wt%, or at least about 90 wt%, and / or up to about 95 wt%, up to about 90 wt%, up to about 85 wt%, up to about 80 wt%, up to about 75 wt%, up to about 70 wt%, up to about 65 wt%, up to about 60 wt%, up to about 55 wt%, or up to about 50 wt%, on a wet weight basis. In some embodiments, the water content of the precursor material is between about 40 and about 50 wt% (50%-60% v / v) on a wet weight basis. If the precursor material has a lower water content, the spray / freeze drying process will be faster because there is less water to be removed.

[0038] Precursor materials include extracts derived from perfume-containing or active-containing plant materials.

[0039] In some embodiments, the precursor material comprises tobacco material and / or tobacco extract.

[0040] The tobacco extract or material may be derived from or be any part of the tobacco plant, including any type of tobacco, as well as tobacco lamina, stems, petioles, veins, scraps, and shorts, or a mixture of two or more thereof. Suitable tobacco extracts or materials include the following types: Virginia or flue-cured tobacco, burley tobacco, oriental tobacco, or a blend of tobacco materials optionally including those listed herein. The tobacco may be expanded, e.g., dry ice expanded tobacco (DIET), or processed by any other means. In some embodiments, the tobacco material may be reconstituted tobacco material. The tobacco may be pre-processed or unprocessed, e.g., solid stem (SS); shredded dried stem (SDS); steam-treated stem (STS); or any combination thereof. The tobacco material may be fermented, cured, uncured, toasted, or otherwise pre-processed. The tobacco material may be provided in the form of cut rag tobacco. Cut rag tobacco may, for example, have a cut width of at least 15 cuts per inch (approximately 5.9 cuts per cm, equivalent to a cut width of approximately 1.7 mm). Cut rag tobacco may be formed from a mixture of tobacco material forms, such as a mixture of one or more of reconstituted tobacco, leaf tobacco, extruded tobacco, and band-cast tobacco.

[0041] The precursor material may comprise at least about 10 wt%, at least about 15 wt%, at least about 20 wt%, at least about 25 wt%, at least about 30 wt%, at least about 35 wt%, or at least about 40 wt%, and / or up to about 60 wt%, up to about 55 wt%, up to about 50 wt%, up to about 45 wt%, or up to about 40 wt% tobacco solids (calculated on a wet weight basis). In some embodiments, the precursor material comprises between about 20 wt% and about 40 wt% tobacco solids (calculated on a wet weight basis).

[0042] In some embodiments, the precursor material comprises at least about 10 wt%, about 20 wt%, at least about 30 wt%, at least about 40 wt%, at least about 50 wt%, at least about 60 wt%, at least about 70 wt%, at least about 80 wt%, at least about 90 wt%, and / or up to about 99 wt%, up to about 90 wt%, up to about 80 wt%, up to about 70 wt%, or up to about 60 wt% tobacco or flavoring-containing or plant material extract-containing active substance (calculated on a wet weight basis). In some embodiments, the precursor material comprises approximately 50 wt% tobacco extract (calculated on a wet weight basis).

[0043] In some embodiments, the precursor material comprises approximately 50% v / v tobacco extract, where the tobacco extract has a tobacco solids content of between about 55% and about 60% v / v, and the total tobacco solids content of the precursor material is between about 27.5% and about 30% v / v.

[0044] In some embodiments, the tobacco extract has a solids content (calculated on a wet weight basis) of between about 40 and about 65 wt%, between about 45 and about 65 wt%, or between about 40 and about 60 wt%. In some embodiments, the moisture content of the tobacco extract is between about 35 wt% and about 65 wt%, or between about 35 and about 55 wt% (calculated on a wet weight basis). In some embodiments, the nicotine content of the tobacco extract is between about 1 wt% and about 5 wt% (calculated on a wet weight basis).

[0045] In some embodiments, the tobacco extract is an aqueous tobacco extract. In some embodiments, the tobacco extract is concentrated and subsequently diluted before being added to the precursor material and dried. In other embodiments, the tobacco extract may not be concentrated and may be used directly in the precursor material.

[0046] In some embodiments, extracts derived from perfume-containing or active-containing plant material include the active.

[0047] As used herein, an active substance can be a bioactive material, which is a material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, dietary supplements, nootropics, and psychotropic drugs. The active substance may be naturally occurring or synthetically obtained. 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 botanical material.

[0048] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0049] In some embodiments, the precursor material may include extracts from other botanical source(s) in addition to or in place of tobacco extract.

[0050] As described herein, an active substance may comprise or be derived from one or more botanical substances, or components, derivatives, or extracts thereof. As used herein, the term "botanical substance" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fiber, stems, roots, seeds, flowers, fruits, pollen, shells, peels, etc. Alternatively, the material may comprise active compounds naturally occurring in the botanical substance or synthetically obtained. The material may be in the form of a liquid, gas, solid, powder, dust, ground particles, granules, pellets, chips, strips, sheets, etc. Examples of botanical substances are tobacco, eucalyptus, star anise, hemp, cocoa, hemp, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, laurel, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea, e.g., green tea or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon The active ingredient is selected from the group consisting of citrus, citrus fruit, citrus aurantium, citrus aurantium, citrus limonene ...The mint may be selected from the following mint varieties: Mentha arventis, grapefruit mint (Mentha cv), Egyptian mint (Mentha niliaca), peppermint (Mentha piperita), cologne mint (Mentha piperita citrata cv), chocolate mint (Mentha piperita cv), curly mint (Mentha spicata crispa), wild mint (Mentha cardifolia), horse mint (Mentha longifolia), pineapple mint (Mentha suaveolens variegata), pennyroyal mint (Mentha pulegium), English spearmint (Mentha spicata cv), and apple mint (Mentha suaveolens).

[0051] In some embodiments, the active substance comprises or is derived from one or more botanical substances, or components, derivatives or extracts thereof, and the botanical substance is tobacco.

[0052] In some embodiments, the active agent comprises or is derived from one or more botanical substances, or components, derivatives or extracts thereof, and the botanical substances are selected from eucalyptus, star anise, cocoa and hemp.

[0053] In some embodiments, the active agent comprises or is derived from one or more botanical substances, or components, derivatives or extracts thereof, and the botanical substances are selected from rooibos and fennel.

[0054] In some embodiments, extracts derived from perfume- or active-containing plant materials are concentrated and then dried. This can make the drying step more efficient, for example, requiring less energy. This can also help provide precursor materials in a form suitable for the selected drying process. In some situations, the concentrated extract can be shipped and then dried, which can result in further cost savings due to the smaller volume and weight of the concentrated extract compared to the non-concentrated extract.

[0055] The precursor material further includes an aerosol-forming material.

[0056] 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. In some embodiments, the aerosol-forming material may include one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0057] 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. In some embodiments, the aerosol-forming material comprises, consists essentially of, or consists of glycerol. In a preferred embodiment, the aerosol-forming agent consists of glycerol. Glycerol provides a visible aerosol when the aerosol-generating device is used. Consumers generally prefer aerosol-generating devices that provide a visible aerosol because they allow consumers to visualize the product and what they are consuming. This makes glycerol a desirable choice as an aerosol-forming material. Propylene glycol has the advantage of being a better flavor carrier than glycerol.

[0058] A combination of aerosol-forming agents with similar or different properties may be used. The aerosol-forming material may act as a plasticizer.

[0059] In some embodiments, the precursor material comprises at least about 1 wt%, at least about 5 wt%, at least about 10 wt%, or at least about 20 wt% aerosol-forming material (calculated on a wet weight basis).

[0060] The precursor material may comprise up to about 40 wt%, up to about 35, up to about 30 wt%, up to about 25 wt%, up to about 20 wt%, or up to about 10 wt% aerosol-forming material (calculated on a wet weight basis).

[0061] In embodiments of the invention in which the aerosol-forming material is glycerol, the precursor material may contain up to 36 wt% glycerol. The inventors have demonstrated that dry weight loading levels of aerosol-forming material up to 36 wt% (calculated on a dry weight basis) are possible.

[0062] The amount of glycerol in the precursor material, and therefore the dry aerosol material, is important because it is both an aerosol-forming material and a plasticizer. If the concentration of glycerol is too high, it can be detrimental to the product's critical temperature during the freeze-drying process, leading to product collapse if the formulation's critical temperature is exceeded. On the other hand, sufficient glycerol should be included to provide an adequate and pleasant aerosol to the consumer.

[0063] In some embodiments, the precursor material further comprises one or more excipients. 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 includes glycerol as the aerosol-forming material. The excipient may also act as a bulking or filler material. Suitable excipients include mannitol, sucrose, trehalose, lactose, sorbitol, raffinose, maltose, dextran 10, dextran 70, dextran 90, maltodextrin, gelatin, agar, cyclodextrin, PEG 2000-6000, and (PVP10k).

[0064] In some embodiments, the precursor material comprises one or more excipients in an amount of about 0 to about 40 wt% on a wet weight basis, hi some embodiments, the precursor material may comprise at least about 1 wt%, at least about 10 wt%, at least about 20 wt%, at least about 30 wt%, and / or up to about 40 wt%, up to about 30%, or up to about 20 wt% of excipients on a wet weight basis.

[0065] In embodiments where the excipient is agar, the precursor material may contain about 0 wt%, about 5 wt%, or about 10 wt% agar. The inventors have found that agar makes the precursor material more viscous, and that the freeze-drying process is easier when the precursor material contains a lower concentration of the agar excipient.

[0066] In some embodiments, the precursor material comprises about 50 wt% tobacco extract, about 0 to about 36 wt% aerosol-forming agent (or about 0 to 15 v / v%), and about 0 to about 40 wt% (37.5 v / v%) excipients. The tobacco extract may comprise about 55 wt% tobacco solids, with the total tobacco solids content of the precursor material being about 27.5 wt%.

[0067] In some embodiments, the precursor material comprises about 50 wt% tobacco extract, up to about 36 wt% (15 v / v%) glycerol, and about 0 to about 40 wt% (37.5 v / v%) excipients. The tobacco extract may comprise about 55 wt% tobacco solids, with the total tobacco solids content of the precursor material being about 27.5 wt%.

[0068] In some embodiments, the precursor material comprises one or more binders, in some embodiments, the one or more binders are selected from the group consisting of thermoreversible gelling agents, such as gelatin, starch, polysaccharides, pectin, cellulose, cellulose derivatives, such as carboxymethylcellulose, and alginates.

[0069] In some embodiments, one or more flavor-modifiers, fragrances, or flavorings are included in the precursor material. As used herein, the terms "flavor" and "flavoring" refer to materials that can be used to create a desired taste, aroma, or other somatic sensation in products for adult consumers, where local regulations permit. They include naturally occurring flavor materials, botanicals, extracts of botanicals, synthetically derived materials, or combinations thereof (e.g., tobacco, hemp, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, crambe, etc.). Lee, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, 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, naswar war), 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, mint oil from any species of mint (Mentha), eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, laurel, macadamia tea, orange peel, rose, tea, e.g. green tea or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, black currant, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chives, Calvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers,They may contain sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners. They may be imitation, synthetic, or natural ingredients, or blends thereof. They may be in any suitable form, for example, liquids such as oils, solids such as powders, or gases.

[0070] In some embodiments, the flavoring agent comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavoring agent comprises cucumber, blueberry, citrus, and / or red berry flavoring ingredients. In some embodiments, the flavoring agent comprises eugenol. In some embodiments, the flavoring agent comprises flavoring ingredients extracted from tobacco. In some embodiments, the flavoring agent comprises flavoring ingredients extracted from cannabis.

[0071] In some embodiments, the fragrance present in the precursor material is derived from an extract derived from a fragrance-containing or active-containing plant material. Additionally or alternatively, fragrances not derived from extracts may be added to the precursor material. In some embodiments, the fragrance is hydrophobic.

[0072] In some embodiments, the flavoring agent may include a sensory agent intended to achieve somatic sensations typically chemically induced and perceived by stimulating the fifth cranial nerve (trigeminal nerve) in addition to or instead of the olfactory or gustatory nerves, and these may include agents that produce heating, cooling, tingling, and numbing effects. Suitable heating agents may be, but are not limited to, vanillyl ethyl ether, and suitable cooling agents may be, but are not limited to, eucolyptol, WS-3.

[0073] In some embodiments, the precursor material includes 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.

[0074] In some embodiments, the precursor material contains a filler component. The filler component is generally a non-tobacco component, i.e., a component that does not contain tobacco-derived components. In some embodiments, the precursor material contains less than 60 wt% of filler by wet weight, e.g., between 1 wt% and 60 wt%, or between 5 wt% and 50 wt%, or between 5 wt% and 30 wt%, or between 10 wt% and 20 wt%.

[0075] When present, the filler may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents, such as molecular sieves. The filler may comprise one or more organic filler materials, such as wood pulp, hemp fiber, cellulose, and cellulose derivatives.

[0076] Spray drying and freeze drying The drying method used to dry the precursor material may be any suitable freeze-drying or spray-drying process. In a small-scale example, the precursor material is freeze-dried using a freeze-drying microscope, for example, a Lyostat freeze-drying microscope.

[0077] In the spray drying process, precursor materials are atomized and rapidly dried using hot gas. The use of spray drying provides the present invention with several advantages: the dry particle size can be controlled and can be constant; tobacco or flavor extracts or materials are heat sensitive, but can still be spray dried at relatively high inlet temperatures; the required residence time in the spray drying equipment is short; and the loss of flavor / volatiles is minimal. This makes the process adaptable to reduce the loss of volatile compounds and maintain the desired flavor of the aerosol-generating material.

[0078] Freeze-drying, also known as lyophilisation or cryodesiccation, is a process in which precursor materials are frozen, their temperature reduced, and water removed via sublimation under reduced pressure. Without wishing to be bound by any particular theory, it is believed that the low processing temperatures and rapid water loss via sublimation avoid changes in the structure, appearance and characteristics of the aerosol-forming material. This process preserves the structure of the precursor materials and reduces the loss and degradation of volatile fragrance compounds.

[0079] The dry aerosol-forming material has a lower water content than the precursor material. The water content may be up to about 0.5 wt%, about 1 wt%, about 2%, about 5 wt%, about 10 wt%, or about 20 wt% (calculated on a wet weight basis). The water content of the dry aerosol-forming material may be reduced by at least about 50 wt%, about 60 wt%, about 70 wt%, about 80 wt%, about 90 wt%, about 95 wt%, about 98 wt%, or about 100 wt% from the precursor material. In some embodiments, the dry aerosol-forming material has a water content of less than about 5 wt%, less than about 4 wt%, less than about 3 wt%, less than about 2 wt%, or less than about 1 wt% (calculated on a wet weight basis) as measured by gas chromatography-thermal conductivity detector (GC-TCD) or Karl Fischer measurement.

[0080] In an exemplary embodiment of the invention, the precursor material comprises burley tobacco extract and a moisture content of 60 wt%. After the freeze-drying process described herein, the dry aerosol-forming material has a moisture content of 3 wt%.

[0081] A lower moisture content of the dry aerosol-forming material is associated with a longer shelf life and stability. However, a very low moisture content is associated with a brittle structure and smaller particle size, and processing may take longer. On the other hand, if the moisture content is too high, the desired increase in stability may not be achieved. The dry aerosol-forming material may also not be as easy to handle as a material with a higher moisture content.

[0082] The inventors have found that precursor materials can be dried via spray drying when they contain higher amounts of excipients. Without wishing to be bound by any particular theory, it is speculated that increasing the amount of excipient in the precursor material increases the glass transition temperature above 100°C, which affects the physical properties of the material and makes it more suitable for spray drying.

[0083] Dry aerosol-generating materials Because dry aerosol-forming materials are stable over a wider range of temperatures and humidities than their corresponding precursor materials, they can be stored and / or transported for longer periods of time without degradation. Without wishing to be bound by any particular theory, it is believed that the low moisture content of dry aerosol-forming materials reduces evaporation of other solvents over time, reducing degradation of nicotine and / or other volatile compounds. The low moisture content also inhibits microbial growth. A benefit of the improved stability of dry aerosol-forming materials is that freezer conditions are not required to store and transport the materials. This facilitates both easier and cheaper storage and transportation. Compared to frozen tobacco materials, dry aerosol-forming materials are also lighter and therefore easier to transport.

[0084] The dry aerosol-generating material can be in any solid form. For example, the dry aerosol-generating material can be in granular, agglomerated, particulate, or powder form. The dry aerosol-generating material can also be in the form of a "cake." The dry aerosol-generating material can then be further processed, as needed, by other suitable steps known to those skilled in the art to provide material in the form of particles of the desired size(s).

[0085] In some embodiments, the dry aerosol-forming material is in the form of a gel. A gelling agent may be added to the dry aerosol-forming material, the precursor material, or may optionally be omitted. The gelling agent may include one or more compounds selected from cellulosic gelling agents, non-cellulosic gelling agents, guar gum, acacia gum, and mixtures thereof.

[0086] In some embodiments, the cellulosic gelling agent is selected from the group consisting of hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose (CMC), hydroxypropyl methyl cellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP), and combinations thereof.

[0087] 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.

[0088] 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.

[0089] The dry aerosol-forming material, e.g., an amorphous solid, may include a colorant. The presence of the colorant can enhance the appearance of the aerosol-forming material. By adding a colorant to the dry aerosol-forming material, the dry aerosol-forming material can be color-matched to other components of the aerosol-forming material or other components of the article that includes the dry aerosol-forming material.

[0090] Various colorants may be used depending on the desired color of the dry aerosol-forming material. The color of the dry aerosol-forming material may be, for example, white, green, red, purple, blue, brown, or black. Other colors are also contemplated. Natural or synthetic colorants, such as natural or synthetic dyes, food-grade colorants, and pharmaceutical-grade colorants, may be used. In certain embodiments, the colorant is caramel, which may impart a brown appearance to the aerosol-forming material. In such embodiments, the color of the aerosol-forming material may be similar to the color of other ingredients (e.g., tobacco material) included with the dry aerosol-forming material. In some embodiments, the addition of a colorant to the dry aerosol-forming material makes the dry aerosol-forming material visually indistinguishable from other ingredients included with or blended with the aerosol-forming material.

[0091] The colorant may be incorporated into the dry aerosol-forming material during its formation (e.g., when forming a slurry with the material that forms the amorphous solid), or the colorant may be applied to the dry aerosol-forming material after its formation (e.g., by spraying the colorant onto the amorphous solid).

[0092] The aerosol-generating material may include an acid. The acid may be an organic acid. In some of these embodiments, the acid may be at least one of a monobasic acid, a dibasic acid, and a tribasic acid. In some such embodiments, the acid may include at least one carboxyl functional group. In some such embodiments, the acid may be at least one of an alpha-hydroxy acid, a carboxylic acid, a dicarboxylic acid, a tricarboxylic acid, and a keto acid. In some such embodiments, the acid may be an alpha-keto acid.

[0093] 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.

[0094] Preferably, the acid is lactic acid. In other embodiments, the acid is benzoic acid. 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. In some embodiments, the acid is levulinic acid.

[0095] The inclusion of an acid is particularly preferred in embodiments in which the aerosol-forming material includes nicotine. In such embodiments, the presence of an acid can stabilize dissolved species in the slurry from which the aerosol-forming material is formed. The presence of an acid can reduce or substantially prevent evaporation of nicotine during drying of the slurry, thereby reducing nicotine loss during production.

[0096] In certain embodiments, the aerosol-forming material comprises a gelling agent, including a cellulosic gelling agent and / or a non-cellulosic gelling agent, an active agent, and an acid.

[0097] In some embodiments, the aerosol-forming 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).

[0098] The aerosol-forming material may include one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD) and THC (tetrahydrocannabinol).

[0099] The aerosol-forming material may include cannabidiol (CBD).

[0100] The aerosol-forming material may include nicotine and cannabidiol (CBD).

[0101] The aerosol-forming material may include nicotine, cannabidiol (CBD) and THC (tetrahydrocannabinol).

[0102] In some embodiments, the dry aerosol-generating material is in the form of granules. The granules may be of any size, cross-sectional shape, or mass. Dry aerosol-generating materials in the form of granules are advantageous due to their high surface area-to-volume ratio, which positively impacts the release of volatiles from the material. This form also facilitates the incorporation of the material into an aerosol delivery system.

[0103] In some embodiments, the dry aerosol-forming material is free-flowing and non-sticky, which aids in handling the dry aerosol-forming material.

[0104] Smaller granule particles have a greater surface area to volume ratio and therefore may exhibit enhanced release of tobacco constituents compared to larger sized particles.

[0105] In some embodiments, the particle size of the dry aerosol-forming material may be selected to provide a desired release profile for one or more components of the dry aerosol-forming material. Generally, smaller particle sizes release components more rapidly and over a shorter period of time during use. Larger particle sizes release components more gradually and over a longer period of time. In some embodiments, particles of different sizes may be selected to provide a release profile that begins rapidly when the aerosol-forming material is first used and continues over extended periods of use.

[0106] In some embodiments, it may be desirable for the particles in the precursor composition to have an average particle size of about 3 mm or less, 1 mm or less, about 0.5 mm or less, or to have an average particle size of about 0.3 mm or less, as measured by sieving.

[0107] 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.

[0108] Particles of the desired size can be formed by grinding, shredding, cutting, or crushing tobacco material. Particles of the desired size can also be formed naturally by spray drying or freeze-drying processes. Suitable equipment for creating such tobacco particles includes, for example, shredders, cutters, or mills, such as hammer mills, roller mills, or other types of commercially available milling machines. The size of the tobacco particles can be easily prepared from a variety of different tobacco materials having the properties described herein and is selected to result in particles that provide a source of easily released tobacco components. Smaller particle sizes may be advantageous for aerosol generation. Without wishing to be bound by any particular theory, smaller particles may have a greater surface area-to-volume ratio, which may improve aerosol generation. It has been found that freeze-dried formulations can easily form particles with an average size of less than 1 mm.

[0109] In some embodiments, the dry aerosol-forming material may comprise at least about 45 wt%, at least about 50 wt%, at least about 60 wt%, at least about 70 wt%, at least about 80 wt%, at least about 90 wt%, or at least about 95 wt% tobacco material or tobacco extract, or flavored or active substance-containing plant material extract (calculated on a dry weight basis). In some embodiments, the dry aerosol-forming material may comprise about 60 to about 80 wt% tobacco extract (calculated on a dry weight basis). In some embodiments, the dry aerosol-forming material may comprise about 3 to 6 wt% nicotine (calculated on a dry weight basis).

[0110] In some embodiments, the dry aerosol-forming material may comprise at least about 45 wt%, at least about 50 wt%, at least about 60 wt%, at least about 70 wt%, at least about 80 wt%, at least about 90 wt%, or at least about 95 wt%, and / or up to about 99 wt%, up to about 98 wt%, up to about 95 wt%, up to about 90 wt%, or up to about 80 wt% tobacco solids (calculated on a dry weight basis). In some embodiments, the dry aerosol-forming material may comprise between about 60 and about 80 wt% tobacco solids (calculated on a dry weight basis).

[0111] In some embodiments, the dry aerosol-forming material may comprise at least about 1 wt%, at least about 5 wt%, at least about 10 wt%, at least about 20 wt%, at least about 30 wt%, or at least about 40 wt% aerosol-forming material (calculated on a dry weight basis). In some embodiments, the dry aerosol-forming material may comprise up to about 40 wt%, up to about 30 wt%, up to about 20 wt%, up to about 15 wt%, up to about 10 wt%, or up to about 5 wt% aerosol-forming material (calculated on a dry weight basis).

[0112] In some embodiments, the dry aerosol-forming material may comprise about 1 to about 34 wt. % or about 17 to about 34 wt. % of the aerosol-forming material (calculated on a dry weight basis). In some embodiments in which the aerosol-forming material is glycerol, the dry aerosol-forming material may comprise about 13 to 34 wt. % of the glycerol (calculated on a dry weight basis).

[0113] In embodiments in which burley tobacco is used, the dry aerosol-forming material may contain 17-36 wt% glycerol. The amount of glycerol in the dry aerosol material is important because it is both an aerosol-forming material and a plasticizer. If the glycerol concentration is too high, it can be detrimental to the product's critical temperature during the freeze-drying process and can result in product collapse if the formulation's critical temperature is exceeded. On the other hand, sufficient glycerol should be included to provide an adequate and pleasant aerosol to the consumer.

[0114] In some embodiments, the aerosol-forming material is included in a precursor material that is dried to form the aerosol-forming material. Additionally or alternatively, the aerosol-forming material may be added to the dried aerosol-forming material after it has been formed.

[0115] In some embodiments, the dry aerosol-forming material may contain at least about 0%, 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 dry aerosol-forming material may contain 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).

[0116] In an exemplary embodiment, the dry aerosol-forming material comprises, on a dry weight basis, about 36 wt% glycerol, about 45 wt% tobacco extract, and about 19 wt% excipients.

[0117] In another exemplary embodiment, the dry aerosol-forming material comprises, on a dry weight basis, about 17-39 wt% glycerol, 41-76 wt% tobacco extract, and 0-28 wt% excipients.

[0118] Incorporation into aerosol generating devices. In some embodiments, the dry aerosol-forming material is provided in a consumable product.

[0119] A consumable is an article comprising an aerosol-forming material intended to be partially or completely consumed during use by a user. A consumable may also comprise one or more other components, such as an aerosol-forming material storage area, an aerosol-forming material transfer component, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and / or an aerosol modifier. A consumable may also comprise an aerosol generator, such as a heater that generates heat during use to generate an aerosol from the aerosol-generating material. The heater may comprise, for example, a combustible material, a material heatable by electrical conduction, or a susceptor. A consumable may be of any shape or size suitable for a smoking device. In a preferred embodiment of the present invention, the consumable is rod-shaped.

[0120] In some embodiments, the dry aerosol-forming material is provided in an aerosol-generating device, such as a tobacco heating product (THP) or a hybrid e-cigarette product. Advantageously, the dry aerosol-forming material may be used directly as a solid substrate, where the dry aerosol-forming material is heated directly without combustion to provide an inhalable aerosol. Heating the material can aerosolize the components of the aerosol-forming material, such as glycerol, nicotine, and / or tobacco flavorings. The dry aerosol-forming material can be stored under low humidity conditions, e.g., less than about 30% humidity, prior to use.

[0121] An additional benefit of dry aerosol-forming materials used directly as solid substrates is that the low moisture content reduces the problems associated with "hot puffs" as known in the art.

[0122] In another embodiment, the dry aerosol-generating material is rehydrated and then provided as a rehydrated aerosol-generating material for incorporation into a delivery system. Such rehydrated aerosol-generating material may be used in a non-combustion aerosol delivery system, e.g., a hybrid device, in which an aerosolizable material, such as an e-liquid, is heated to generate vapor and / or aerosol, which passes through or over the tobacco-containing aerosol-generating material to pick up components, including nicotine and (tobacco-derived) flavors and aromas. The rehydrated dry aerosol-generating material may be a "slurry." The rehydrated dry aerosol-generating material may be a gel. The dry aerosol-generating material may be rehydrated with an excess of water, or with a suitable amount of water consistent with the requirements of the final product. For example, some embodiments of the present invention may be rehydrated with a 20:1 excess of water or a 6:1 excess of water.

[0123] In some embodiments, the moisture content of the rehydrated dry aerosol-forming material is at least about 10%, at least about 20%, at least about 30%, at least about 40%, at least about 50%, at least about 60%, at least about 70%, at least about 80%, or at least about 90%.

[0124] In some embodiments, the dry aerosol-forming material may be rehydrated by exposing the dry aerosol-forming material to an ambient or humid environment, which may have a humidity of at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 50%, or at least about 60%.

[0125] In another aspect, the dry aerosol-forming material is rehydrated and applied to a web or fibrous paper material to provide reconstituted tobacco. This process is similar to existing processes for preparing reconstituted tobacco by applying tobacco extract to fibrous paper material, and can be modified by replacing the tobacco extract with the rehydrated aerosol-forming material. This is advantageous because the aerosol-forming material can be incorporated into existing manufacturing processes, but with an improved shelf life as described herein.

[0126] "Reconstituted tobacco paper" refers to tobacco material formed by a process in which tobacco stock is extruded with a solvent to obtain a residue containing a soluble extract and fibrous material, and then the extract (usually after concentration and optionally further processing) is recombined with the fibrous material from the residue (usually after purification of the fibrous material and optionally with the addition of a portion of non-tobacco fiber) by depositing the extract onto the fibrous material. The recombination process is similar to that for papermaking.

[0127] The reconstituted tobacco described herein may be prepared by methods known to those skilled in the art for preparing reconstituted tobacco.

[0128] Delivery System The delivery systems described herein can be combustion-based aerosol delivery systems, non-combustion-based aerosol delivery systems, or aerosol-free delivery systems.

[0129] As used herein, the term "delivery system" is intended to encompass a system that delivers at least one substance to a user, including: Combustion-type aerosol delivery systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or hand-rolled or handmade cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smoking materials); Non-combustion aerosol delivery systems that release compounds from aerosol-forming materials without burning the aerosol-forming materials, such as hybrid systems that generate aerosols using a combination of electronic cigarettes, tobacco heating products, and aerosol-forming materials; and Aerosol-free delivery systems that deliver at least one substance (which may or may not contain nicotine) to a user orally, nasally, transdermally, or otherwise, without forming an aerosol, including, but not limited to, lozenges, gums, patches, articles comprising inhalable powders, and oral products such as oral tobacco (including snus or moist snuff, in which at least one substance may or may not contain nicotine). Examples include:

[0130] According to the present disclosure, a "combustion-type" aerosol delivery system is one in which the component aerosol-forming materials (or components thereof) of the aerosol delivery system are combusted or burned during use to facilitate delivery of at least one substance to the user.

[0131] In some embodiments, the delivery system is a combustion-type aerosol delivery system, for example, a system selected from the group consisting of a cigarette, a cigarillo, and a cigar.

[0132] In some embodiments, the present disclosure relates to components for use in combustion-type aerosol delivery systems, for example, aerosol modifier-releasing components such as filters, filter rods, filter segments, tobacco rods, spills, capsules, threads, or beads, or papers such as plug wrap, tipping paper, or cigarette paper.

[0133] According to this disclosure, a "non-combustion" aerosol delivery system is one in which the component aerosol-forming materials (or components thereof) of the aerosol delivery system are not combusted or burned during use to facilitate delivery of at least one substance to a user.

[0134] In some embodiments, the delivery system is a non-combustion aerosol delivery system, for example, a powdered non-combustion aerosol delivery system.

[0135] 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.

[0136] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. An example of such a system is a tobacco heating system.

[0137] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates aerosol using a combination of aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials may be, for example, in solid, liquid, or gel form and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may, for example, include tobacco or non-tobacco products.

[0138] Typically, a non-combustion aerosol delivery system may include a non-combustion aerosol delivery device and a consumable item for use with the non-combustion aerosol delivery device.

[0139] In some embodiments, the present disclosure relates to consumables that include aerosol-generating materials and are configured for use with non-combustion aerosol delivery devices. These consumables may be referred to as articles throughout this disclosure.

[0140] In some embodiments, the non-combustion aerosol delivery system, e.g., the non-combustion aerosol delivery device, may include a power source and a controller. The power source may be, for example, an electrical power source or a heat generating power source. In some embodiments, the heat generating power source includes a carbon substrate that may be energized to distribute power in the form of heat to an aerosol-generating or heat transfer material proximate to the heat generating power source.

[0141] In some embodiments, the non-combustion aerosol delivery system may include a consumable receiving area, an aerosol generator, an aerosol-generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0142] In some embodiments, a consumable for use with a non-combustion type aerosol delivery device may comprise an aerosol-generating material, 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.

[0143] 1 is a side cross-sectional view of a consumable or article 1 for use in an aerosol delivery system. Article 1 comprises a mouthpiece segment 2 and an aerosol-generation segment 3.

[0144] The aerosol-generating segment 3 is in the form of a cylindrical rod and comprises a dry or rehydrated aerosol-generating material 4. The dry or rehydrated aerosol-generating material can be any of the materials discussed herein.

[0145] Although described above in the form of a rod, the aerosol-generating segment 3 may be provided in other forms, for example in a plug, pouch or packet of material within the article.

[0146] The mouthpiece segment 2 of the illustrated embodiment comprises a body of material 5, for example, fiber or filament tow.

[0147] The rod-shaped consumable 1 further comprises a wrapping 6 , for example a wrapping paper, surrounding the mouthpiece segment 2 and the aerosol-generation segment 3 .

[0148] 2 shows an example of a non-combustion aerosol delivery device 100 for generating an aerosol from an aerosol-generating medium / material, such as the aerosol-generating material of a consumable 110 as described herein. Broadly speaking, device 100 may be used to heat a replaceable article 110 comprising an aerosol-generating medium, such as article 1 as illustrated in FIG. 1 or as described elsewhere herein, to generate an aerosol or other inhalable medium that is inhaled by a user of device 100. Device 100 and replaceable article 110 together form a system.

[0149] The device 100 comprises a housing 102 (in the form of an outer cover) that surrounds and contains the various components of the device 100. The device 100 has an opening 104 at one end through which an item 110 can be inserted for heating by the heating assembly. In use, the item 110 may be fully or partially inserted into the heating assembly where it can be heated by one or more components of the heating assembly.

[0150] The device 100 in this example includes a first end member 106 with a lid 108 that is movable relative to the first end member 106 closer to the opening 104 when the item 110 is not in position. In Figure 2, the lid 108 is shown in an open configuration; however, the lid 108 can be moved to a closed configuration. For example, a user can slide the lid 108 in the direction of arrow "B."

[0151] Device 100 may also include a user-operable control element 112, such as a button or switch, which, when pressed, operates device 100. For example, a user can activate device 100 by operating switch 112.

[0152] Device 100 may also include an electrical component, such as a socket / port 114, which can receive a cable for charging a battery in device 100. For example, socket 114 may be a charging port, such as a USB charging port.

[0153] In some embodiments, the substance to be delivered may be an aerosol-generating material or a material not intended to be aerosolized, either of which may optionally include one or more active ingredients, one or more flavoring agents, one or more aerosol-forming materials, and / or one or more other functional materials.

[0154] In some embodiments, the aerosol-forming materials described herein are not used to generate an aerosol. Rather, the so-called aerosol-forming materials are used in an aerosol-free delivery system that delivers at least one component from the aerosol-forming material to a user via oral, nasal, transdermal, or any other suitable route of administration without forming an aerosol. In some embodiments, the aerosol-forming material is incorporated into a product selected from the group consisting of a lozenge, a gum, a pouch, a patch, and an inhalable powder.

[0155] stability The present invention enjoys the advantage of having a longer shelf life than other tobacco extracts.

[0156] The nicotine content of the precursor and dried aerosol-forming material after the freeze-drying process is calculated to indicate the amount of nicotine retained after processing. The nicotine recovery of the dried aerosol-forming material compared to the original tobacco extract is at least about 76 wt% on a dry weight basis. The nicotine recovery of the dried aerosol-forming material compared to the original tobacco extract may be at least about 60%, at least about 70%, at least about 75%, at least about 80%, or at least about 90% on a dry weight basis.

[0157] The glycerol content of the precursor and dry aerosol-forming material after the freeze-drying process is calculated to indicate the amount of glycerol retained after processing. The glycerol recovery of the dry aerosol-forming material compared to the precursor material is at least about 85%. The glycerol recovery of the dry aerosol-forming material compared to the precursor material may be at least about 70%, at least about 75%, at least about 80%, at least about 85%, at least about 90%, or at least about 95% on a dry weight basis.

[0158] Example 1 In a first test, the precursor material consisted essentially of aqueous tobacco extract and glycerol. The aqueous tobacco extract was further diluted with glycerol to about 24 wt% (calculated on a dry weight basis). The burley aqueous tobacco extract had a tobacco solids content of about 40 wt% and a moisture content of about 60 wt%. The precursor material was dried via freeze-drying.

[0159] Example 2 In further tests, the precursor material consisted essentially of aqueous tobacco extract, glycerol, and dextran 70. The glycerol content ranged from about 0 to about 15% v / v, or up to about 36% by weight, calculated on a dry weight basis. The precursor material was dried via freeze-drying.

[0160] 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. It is understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein are not intended to be limitations on the scope of the invention as defined by the claims or equivalents thereof, and that other embodiments may be utilized and changes may be made without departing from the scope of the invention as claimed. Various embodiments of the present invention may suitably comprise, consist of, or consist essentially of any suitable combination of elements, components, features, parts, steps, means, etc., of the present disclosure other than those specifically described herein. Furthermore, the present disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. A dry aerosol-forming material comprising a spray-dried or freeze-dried precursor material comprising an extract derived from perfume-containing and / or active-containing plant material and an aerosol-forming material.

2. 10. The dry aerosol-forming material of claim 1, wherein the aerosol-forming material is glycerol.

3. 3. The dry aerosol-forming material of claim 1, wherein the precursor material further comprises at least one excipient.

4. 4. The dry aerosol-forming material of claim 3, wherein the excipient is one or more selected from the group consisting of mannitol, sucrose, trehalose, lactose, sorbitol, raffinose, maltose, dextran 10, dextran 70, dextran 90, maltodextrin, gelatin, agar, cyclodextrin, PEG 2000-6000, and polyvinylpyrrolidone (PVP) (10k).

5. 5. The dry aerosol-forming material of claim 1, wherein the precursor material comprises from about 10 to about 95% by weight of an extract derived from a fragrance-containing or active-containing plant material.

6. 6. The dry aerosol-forming material of claim 1, wherein the precursor material comprises from about 1 to about 36% by weight of the aerosol-forming material.

7. 7. The dry aerosol-forming material of claim 1, wherein the precursor material comprises from about 0 to about 40% by weight of an excipient.

8. 8. The dry aerosol-forming material of claim 1, comprising from about 99 to about 45% by weight of a dry extract derived from the fragrance-containing or active-containing plant material.

9. The dry aerosol-forming material of any one of claims 1 to 8, comprising from about 1 to about 34% by weight of the aerosol-forming material.

10. 10. The dry aerosol-forming material of claim 1, comprising from about 0 to about 25% by weight of an excipient.

11. 11. The dry aerosol-forming material of any one of claims 1 to 10, wherein the plant material is selected from the group consisting of tobacco, eucalyptus, star anise, cocoa, and hemp.

12. 12. The dry aerosol-forming material of any one of claims 1 to 11, wherein the extract from perfume-containing or active-substance-containing plant material is an aqueous extract.

13. 13. The dry aerosol-forming material of claim 12, wherein the extract from flavor-containing or active-substance-containing plant material is an aqueous tobacco extract.

14. 14. The dry aerosol-forming material of claim 13, comprising about 40 to about 99 weight percent tobacco solids.

15. The dry aerosol-forming material of any one of claims 1 to 14, in the form of granules.

16. 15. The dry aerosol-forming material of claim 14, wherein the granules have a particle size of up to about 3 mm.

17. 17. The dry aerosol-forming material of any one of claims 1 to 16, having a moisture content of about 5% or less.

18. 18. The dry aerosol-forming material of any one of claims 1 to 17 for use in an aerosol delivery system.

19. A non-combustion aerosol delivery system comprising the dry aerosol-forming material of any one of claims 1 to 17.

20. A method for providing a dry aerosol-forming material, the method comprising spray drying or freeze drying a precursor material comprising an extract derived from a fragrance-containing and / or active-containing plant material and an aerosol-forming material.

21. A method of providing an aerosol-forming material, the method comprising contacting the dry aerosol-forming material of any one of claims 1 to 17 with water.

22. 22. The method of claim 21, wherein contacting the dry aerosol-forming material with water comprises exposing the dry aerosol-forming material to a humid environment.

23. 23. The method of claim 21 or 22, wherein the aerosol-forming material is provided in the form of a solid, liquid, or gel aerosol-forming material.

24. 24. The method of claim 23, wherein a solid amorphous material is formed from the dry aerosol-forming material.

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