Consumables for heated tobacco products

Abstract

A method of making a consumable for a heated tobacco product includes preparing a tobacco powder having a desired powder size. The method further includes preparing wet tobacco granules by admixing the tobacco powder with a binder and a solvent. The method further includes preparing tobacco granules by removing at least a portion of the solvent from the wet tobacco granules. The method further includes preparing a filler by admixing the tobacco granules with an aerosol former. The method further includes preparing a consumable including the filler.

Description

Atty. Dkt. No. 24000NV-001126-WO-POACONSUMABLES FOR HEATED TOBACCO PRODUCTSBACKGROUNDCross-Reference to Related Applications

[0001] This Application claims the benefit of U.S. Provisional Application No. 63 / 729,530, filed on December 9, 2024, the entire disclosure of which is incorporated herein by reference thereto in its entirety.Field

[0002] The present disclosure relates to aerosol-generating substrates and consumables including the same, such as for use in aerosol-generating devices, configured to generate an aerosol without involving a substantial pyrolysis of an aerosol-forming substrate.Description of Related Art

[0003] Some electronic devices are configured to heat an aerosol-forming substrate, such as a plant material, to a temperature that is sufficient to release constituents of the plant material while keeping the temperature below a combustion point of the plant material so as to avoid any substantial pyrolysis of the plant material. Such devices may be referred to as aerosolgenerating devices (e.g., heated tobacco or heated tobacco product aerosol-generating devices), and the plant material heated may be tobacco and / or cannabis. In some instances, the plant material may be introduced directly into a heating chamber of an aerosol -generating device. In other instances, the plant material may be pre-packaged in individual containers to facilitate insertion and removal from an aerosol-generating device.Atty. Dkt. No. 24000NV-001126-WO-POASUMMARY

[0004] At least one example embodiment relates to a method of making a consumable for a heated tobacco product.

[0005] In at least one example embodiment, the method includes preparing a tobacco powder having a desired powder size. The method further includes preparing wet tobacco granules by admixing the tobacco powder with a binder and a solvent. The method further includes preparing tobacco granules by removing at least a portion of the solvent from the wet tobacco granules. The method further includes preparing a filler by admixing the tobacco granules with an aerosol former. The method further includes preparing a consumable including the filler.

[0006] In at least one example embodiment, the preparing a consumable includes adding the filler to an annular space of a container such that the consumable includes the container having the filler therein. An outer surface of the container is configured to be heated by an external heater.

[0007] In at least one example embodiment, the filler in the consumable has a bulk density ranging from 0.2 g / cm3to 1 g / cm3.

[0008] In at least one example embodiment, the filler is configured to be constantly heated for a series of 10 puffs to release a total amount of released nicotine. The filler is configured to release less than 60 weight percent of the total amount of released nicotine during a first 5 puffs of the series of 10 puffs.

[0009] In at least one example embodiment, the filler is configured to release nicotine in an amount ranging from 35 weight percent to 60 weight percent of the total amount of released nicotine during the first 5 puffs.

[0010] In at least one example embodiment, the desired powder size ranges from 0.075 mm to 0.25 mm.Atty. Dkt. No. 24000NV-001126-WO-POA

[0011] In at least one example embodiment, the preparing tobacco granules includes extruding the wet tobacco granules to form a tobacco extrudate. The preparing tobacco granules further includes granulating the tobacco extrudate to a desired tobacco granule diameter.

[0012] In at least one example embodiment, the desired tobacco granule diameter ranges from 0.2 mm to 2.5 mm.

[0013] In at least one example embodiment, the tobacco extrudate is rod-shaped.

[0014] In at least one example embodiment, the granulating includes marumerizing the tobacco extrudate to form the tobacco granules. The tobacco granules are generally spherical.

[0015] In at least one example embodiment, the preparing the wet tobacco granules further includes admixing a flavoring agent with the tobacco powder, the solvent, and the binder.

[0016] In at least one example embodiment, the preparing the wet tobacco granules includes admixing the tobacco powder, the solvent, and the binder in a mixer.

[0017] In at least one example embodiment, the preparing the filler includes absorbing the aerosol former into the tobacco granules for a duration ranging from 2 hours to 10 days.

[0018] In at least one example embodiment, the preparing tobacco granules includes heating the wet tobacco granules in an oven for a duration ranging from 10 minutes to 60 hours, at a temperature ranging from 40°C to 90°C.

[0019] In at least one example embodiment, the preparing tobacco granules includes fluidizing the wet tobacco granules in a fluidized bed for a duration ranging from 5 minutes to 2 hours at a temperature ranging from 30°C to 90°C.

[0020] In at least one example embodiment, the preparing the wet tobacco granules includes admixing the tobacco powder with the solvent and the binder. The binder includes cellulose, microcrystalline cellulose, hydroxypropylcellulose, methylcellulose, ethyl cellulose, hydroxypropylmethylcellulose, sodium carboxymethylcellulose, starch, pregelatinized starch, gum acacia, maltodextrin, povidone, polyvinyl alcohol, polyvinylethylene glycol, polyvinylAtty. Dkt. No. 24000NV-001126-WO-POAalcohol graft polyethylene glycol copolymer, polymethacrylate, sugar alcohol, or any combination thereof.

[0021] In at least one example embodiment, the binder includes the hydroxypropylmethylcellulose.

[0022] In at least one example embodiment, tobacco granules include the hydroxypropylmethylcellulose at less than or equal to 5 weight percent.

[0023] In at least one example embodiment, the aerosol former includes propylene glycol, glycerol, butylene glycol, or any combination thereof.

[0024] At least one example embodiment relates to a method of making a consumable.

[0025] In at least one example embodiment, the method includes preparing wet granules by admixing a botanical powder with a binder and a solvent. The botanical powder has a size ranging from 0.075 mm to 0.25 mm. The method further includes preparing dry granules by removing at least a portion of the solvent from the wet granules. The dry granules have a diameter ranging from about 0.2 mm to about 2.5 mm. The method further includes preparing a substrate by admixing the dry granules with an aerosol former and an additive. The method further includes preparing a consumable including the substrate.

[0026] In at least one example embodiment, the additive is a flavoring agent.

[0027] At least one example embodiment relates to a consumable for a heated tobacco product, the consumable.

[0028] In at least one example embodiment, the consumable includes a container and a filler. The container defines an annular interior region. An outer surface of the container is configured to be heated by an external heater. The filler is in the annular interior region. The filler includes

[0029] tobacco granules. The tobacco granules are in the annular interior region and have a bulk density ranging from 0.2 g / cm3to 1 g / cm3. The tobacco granules include a binder, tobaccoAtty. Dkt. No. 24000NV-001126-WO-POAparticles, and an aerosol former. The binder includes cellulose, microcrystalline cellulose, hydroxypropylcellulose, methylcellulose, ethyl cellulose, hydroxypropylmethylcellulose, sodium carboxymethylcellulose, starch, pregelatinized starch, gum acacia, maltodextrin, povidone, polyvinyl alcohol, polyvinylethylene glycol, polyvinyl alcohol graft polyethylene glycol copolymer, polymethacrylate, sugar alcohol, or any combination thereof. The tobacco particles have a size ranging from 0.075 mm to 0.25 mm. The aerosol former is admixed with the tobacco granules.

[0030] In at least one example embodiment, the filler further includes an additive.

[0031] In at least one example embodiment, the additive includes a flavoring agent.

[0032] In at least one example embodiment, the binder includes hydroxypropylmethylcellulose.

[0033] In at least one example embodiment, the tobacco granules include the hydroxypropylmethylcellulose in an amount less than or equal to about 5 weight percent.

[0034] In at least one example embodiment, the binder includes the microcrystalline cellulose.

[0035] In at least one example embodiment, the aerosol former includes propylene glycol, glycerol, butylene glycol, or any combination thereof.

[0036] In at least one example embodiment, the tobacco granules define a diameter ranging from 0.2 mm to 2.5 mm.

[0037] At least one example embodiment relates to a method of making a consumable for a heated tobacco product.

[0038] In at least one example embodiment, the method includes admixing a tobacco powder with a binder and a solvent to form wet tobacco granules. The method further includes removing at least a portion of the solvent from the wet tobacco granules to form tobacco granules. The method further includes admixing the tobacco granules with an aerosol formerAtty. Dkt. No. 24000NV-001126-WO-POAto form a filler. The method further includes at least partially filling a portion of a consumable with the filler.

[0039] In at least one example embodiment, the at least partially filling a portion of a consumable includes adding the filler to an annular space of a container such that the consumable includes the container having the filler therein. An outer surface of the container is configured to be heated by an external heater.

[0040] In at least one example embodiment, the at least partially filling a portion of a consumable includes adding the filler such that the filler has a bulk density ranging from 0.2 g / cm3to 1 g / cm3.

[0041] In at least one example embodiment, the tobacco powder has a desired powder size ranging from 0.075 mm to 0.25 mm.

[0042] In at least one example embodiment, the removing includes extruding the wet tobacco granules to form a tobacco extrudate. The removing further includes granulating the tobacco extrudate to a desired tobacco granule size.

[0043] In at least one example embodiment, the desired tobacco granule diameter ranges from 0.2 mm to 2.5 mm.

[0044] In at least one example embodiment, the tobacco extrudate is rod-shaped.

[0045] In at least one example embodiment, the granulating includes marumerizing the tobacco extrudate to form the tobacco granules. The tobacco granules is generally spherical.

[0046] In at least one example embodiment, the admixing a tobacco powder further includes admixing a flavoring agent with the tobacco powder, the solvent, and the binder.

[0047] In at least one example embodiment, the admixing a tobacco powder further includes admixing the tobacco powder, the solvent, and the binder in a mixer.Atty. Dkt. No. 24000NV-001126-WO-POA

[0048] In at least one example embodiment, the admixing the tobacco granules includes absorbing the aerosol former into the tobacco granules for a duration ranging from 2 hours to 10 days.

[0049] In at least one example embodiment, the removing includes heating the wet tobacco granules in an oven for a duration ranging from 10 minutes to 60 hours, at a temperature ranging from 40°C to 90°C.

[0050] In at least one example embodiment, the removing includes fluidizing the wet tobacco granules in a fluidized bed for a duration ranging from 5 minutes to 2 hours at a temperature ranging from 30°C to 90°C.

[0051] In at least one example embodiment, the admixing a tobacco powder includes admixing the tobacco powder with the solvent and the binder, the binder including cellulose, microcrystalline cellulose, hydroxypropylcellulose, methylcellulose, ethyl cellulose, hydroxypropylmethylcellulose, sodium carboxymethylcellulose, starch, pregelatinized starch, gum acacia, maltodextrin, povidone, polyvinyl alcohol, polyvinylethylene glycol, polyvinyl alcohol graft polyethylene glycol copolymer, polymethacrylate, sugar alcohol, or any combination thereof.

[0052] In at least one example embodiment, the binder includes the hydroxypropylmethylcellulose.

[0053] In at least one example embodiment, tobacco granules include the hydroxypropylmethylcellulose at less than or equal to 5 weight percent.

[0054] In at least one example embodiment, the aerosol former includes propylene glycol, glycerol, butylene glycol, or any combination thereof.

[0055] At least one example embodiment relates to a heated tobacco product. The heated tobacco product includes a device body and a consumable. The device body includes a housing defining a chamber, a heater, and a power supply. The power supply is configured to supplyAtty. Dkt. No. 24000NV-001126-WO-POApower to the heater. The consumable is configured to be at least partially received in the chamber. The consumable includes a container and a filler. The container defines an annular interior region. An outer surface of the container is configured to be heated by the external heater. The filler is in the annular interior region. The filler includes tobacco granules and an aerosol former. The tobacco granules are in the annular interior region and have a bulk density ranging from 0.2 g / cm3to 1 g / cm3. The tobacco granules include a binder and tobacco particles. The binder includes cellulose, microcrystalline cellulose, hydroxypropylcellulose, methylcellulose, ethyl cellulose, hydroxypropylmethylcellulose, sodium carboxymethylcellulose, starch, pregelatinized starch, gum acacia, maltodextrin, povidone, polyvinyl alcohol, polyvinylethylene glycol, polyvinyl alcohol graft polyethylene glycol copolymer, polymethacrylate, sugar alcohol, or any combination thereof, tobacco particles having a size ranging from 0.075 mm to 0.25 mm. The aerosol former is admixed with the tobacco granules.

[0056] In at least one example embodiment, the filler further includes an additive.

[0057] In at least one example embodiment, the additive includes a flavoring agent.

[0058] In at least one example embodiment, the binder includes hydroxypropylmethylcellulose.

[0059] In at least one example embodiment, the tobacco granules include the hydroxypropylmethylcellulose in an amount less than or equal to about 5 weight percent.

[0060] In at least one example embodiment, the binder includes the microcrystalline cellulose.

[0061] In at least one example embodiment, the aerosol former includes propylene glycol, glycerol, butylene glycol, or any combination thereof.

[0062] In at least one example embodiment, the tobacco granules define a diameter ranging from 0.2 mm to 2.5 mm.Atty. Dkt. No. 24000NV-001126-WO-POA

[0063] At least one example embodiment relates to a method of making a filler for a heated tobacco product.

[0064] In at least one example embodiment, the method includes preparing a tobacco powder having a desired powder size. The method further includes preparing wet tobacco granules by admixing the tobacco powder with a binder and a solvent. The method further includes preparing tobacco granules by removing at least a portion of the solvent from the wet tobacco granules. The method further includes preparing a filler by admixing the tobacco granules with an aerosol former.

[0065] In at least one example embodiment, the filler is configured to be constantly heated for a series of 10 puffs to release a total amount of released nicotine. The filler is configured to release less than 60 weight percent of the total amount of released nicotine during a first 5 puffs of the series of 10 puffs.

[0066] In at least one example embodiment, the filler is configured to release nicotine in an amount ranging from 35 weight percent to 60 weight percent of the total amount of released nicotine during the first 5 puffs.

[0067] In at least one example embodiment, the desired powder size ranges from 0.075 mm to 0.25 mm.

[0068] In at least one example embodiment, the preparing tobacco granules includes extruding the wet tobacco granules to form a tobacco extrudate. The preparing tobacco granules further includes granulating the tobacco extrudate to a desired tobacco granule diameter.

[0069] In at least one example embodiment, the desired granule diameter ranges from 0.2 mm to 2.5 mm.

[0070] In at least one example embodiment, the tobacco extrudate is rod-shaped.

[0071] In at least one example embodiment, the granulating includes marumerizing the tobacco extrudate to form the tobacco granules. The tobacco granules are generally spherical.Atty. Dkt. No. 24000NV-001126-WO-POA

[0072] In at least one example embodiment, the preparing the wet tobacco granules further includes admixing a flavoring agent with the tobacco powder, the solvent, and the binder.

[0073] In at least one example embodiment, the preparing the wet tobacco granules includes admixing the tobacco powder, the solvent, and the binder in a mixer.

[0074] In at least one example embodiment, the preparing the filler includes absorbing the aerosol former into the tobacco granules for a duration ranging from 2 hours to 10 days.

[0075] In at least one example embodiment, the preparing tobacco granules includes heating the wet tobacco granules in an oven for a duration ranging from 10 minutes to 60 hours, at a temperature ranging from 40°C to 90°C.

[0076] In at least one example embodiment, the preparing tobacco granules includes fluidizing the wet tobacco granules in a fluidized bed for a duration ranging from 5 minutes to 2 hours at a temperature ranging from 30°C to 90°C.

[0077] In at least one example embodiment, the preparing the wet tobacco granules includes admixing the tobacco powder with the solvent and the binder. The binder includes cellulose, microcrystalline cellulose, hydroxypropylcellulose, methylcellulose, ethyl cellulose, hydroxypropylmethylcellulose, sodium carboxymethylcellulose, starch, pregelatinized starch, gum acacia, maltodextrin, povidone, polyvinyl alcohol, polyvinylethylene glycol, polyvinyl alcohol graft polyethylene glycol copolymer, polymethacrylate, sugar alcohol, or any combination thereof.

[0078] In at least one example embodiment, the binder includes the hydroxypropylmethylcellulose.

[0079] In at least one example embodiment, tobacco granules include the hydroxypropylmethylcellulose at less than or equal to 5 weight percent.

[0080] In at least one example embodiment, the aerosol former includes propylene glycol, glycerol, butylene glycol, or any combination thereof.Atty. Dkt. No. 24000NV-001126-WO-POA

[0081] At least one example embodiment relates to a method of making a composition.

[0082] In at least one example embodiment, the method includes preparing wet granules by admixing a botanical powder with a binder and a solvent. The botanical powder has a size ranging from 0.075 mm to 0.25 mm. The method further includes preparing dry granules by removing at least a portion of the solvent from the wet granules. The dry granules have a diameter ranging from about 0.2 mm to about 2.5 mm. The method further includes preparing a composition by admixing the dry granules with an aerosol former and an additive.

[0083] In at least one example embodiment, the additive is a flavoring agent.BRIEF DESCRIPTION OF THE DRAWINGS

[0084] The various features and advantages of the non-limiting embodiments herein may become more apparent upon review of the detailed description in conjunction with the accompanying drawings. The accompanying drawings are merely provided for illustrative purposes and should not be interpreted to limit the scope of the claims. The accompanying drawings are not to be considered as drawn to scale unless explicitly noted. For purposes of clarity, various dimensions of the drawings may have been exaggerated.

[0085] FIG. l is a perspective view of an aerosol -forming substrate in loose form according to at least one example embodiment.

[0086] FIG. 2 is a perspective view of a consumable according to at least one example embodiment.

[0087] FIG. 3A is a sectional view of the consumable of FIG. 2 taken at line III— III of FIG.2 according to at least one example embodiment.

[0088] FIG. 3B is a schematic view of the consumable of FIG. 3A illustrating airflow according to at least one example embodiment.Atty. Dkt. No. 24000NV-001126-WO-POA

[0089] FIG. 4 is a perspective view of the tobacco consumable of FIG. 2 including an external heater according to at least one example embodiment.

[0090] FIG. 5 is a perspective view of a heated tobacco device including the tobacco consumable and heater of FIG. 4 according to at least one example embodiment.

[0091] FIG. 6 is a schematic diagram of the device of FIG. 5 according to at least one example embodiment.

[0092] FIG. 7 is a flowchart illustrating a method of manufacturing an aerosol -forming substrate according to at least one example embodiment.DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

[0093] Some detailed example embodiments are disclosed herein. However, specific structural and functional details disclosed herein are merely representative for purposes of describing example embodiments. Example embodiments may, however, be embodied in many alternate forms and should not be construed as limited to only the example embodiments set forth herein.

[0094] Accordingly, while example embodiments are capable of various modifications and alternative forms, example embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that there is no intent to limit example embodiments to the particular forms disclosed, but to the contrary, example embodiments are to cover all modifications, equivalents, and alternatives thereof. Like numbers refer to like elements throughout the description of the figures.

[0095] It should be understood that when an element or layer is referred to as being "on," "connected to," "coupled to," “attached to,” “adjacent to,” or "covering" another element or layer, it may be directly on, connected to, coupled to, attached to, adjacent to or covering the other element or layer or intervening elements or layers may be present. In contrast, when anAtty. Dkt. No. 24000NV-001126-WO-POAelement is referred to as being "directly on," "directly connected to," or "directly coupled to" another element or layer, there are no intervening elements or layers present. Like numbers refer to like elements throughout the specification. As used herein, the term "and / or" includes any and all combinations or sub-combinations of one or more of the associated listed items.

[0096] It should be understood that, although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and / or sections, these elements, components, regions, layers, and / or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer, or section from another region, layer, or section. Thus, a first element, component, region, layer, or section discussed below could be termed a second element, component, region, layer, or section without departing from the teachings of example embodiments.

[0097] Spatially relative terms (e.g., "beneath," "below," "lower," "above," "upper," and the like) may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It should be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. Thus, the term "below" may encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0098] The terminology used herein is for the purpose of describing various example embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "includes,"Atty. Dkt. No. 24000NV-001126-WO-POA"including," "comprises," and / or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0099] While the term “same” or “identical” is used in description of example embodiments, it should be understood that some imprecisions may exist. Thus, when one element is referred to as being the same as another element, it should be understood that an element or a value is the same as another element within a desired manufacturing or operational tolerance range (e.g., ±10%).

[0100] When the terms "about" or “substantially” are used in this specification in connection with a numerical value, it is intended that the associated numerical value includes a manufacturing or operational tolerance (e.g., ±10%) around the stated numerical value. Moreover, when the words "generally" and "substantially" are used in connection with geometric shapes, it is intended that precision of the geometric shape is not required but that latitude for the shape is within the scope of the disclosure. Further, regardless of whether numerical values or shapes are modified as "about" or "substantially," it will be understood that these values and shapes should be construed as including a manufacturing or operational tolerance (e.g., ±10%) around the stated numerical values or shapes.

[0101] The controller may include processing circuitry such as hardware including logic circuits; a hardware / software combination such as a processor executing software stored in a memory; or a combination thereof. For example, the processing circuitry more specifically may include, but is not limited to, a central processing unit (CPU), an arithmetic logic unit (ALU), a digital signal processor, a microcomputer, a field programmable gate array (FPGA), a System-on-Chip (SoC), a programmable logic unit, a microprocessor, application-specific integrated circuit (ASIC), etc.Atty. Dkt. No. 24000NV-001126-WO-POA

[0102] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, including those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0103] Some electronic devices are configured to heat a material (e.g., plant material) to a temperature that is sufficient to release constituents of the material while keeping the temperature below its ignition temperature so as to avoid a self-sustaining burning or a self-sustaining combustion of the material (i.e., in contrast to where a material is lit, such as lit-end cigarettes). Such devices may be characterized as generating an aerosol of constituents released by heating, and may be referred to as heat-not-burn aerosol-generating devices, or heat-not-burn devices.

[0104] It is understood that heating of a material below its ignition temperature may, in some circumstances, produce incidental and insubstantial levels of oxidized or other thermal decomposition byproducts. However, in some embodiments, the heating in aerosol-generating devices is below the pyrolysis temperature of the material so as to produce an aerosol having no or insubstantial levels of thermal decomposition byproducts of the material. Thus, in an example embodiment, pyrolysis of the material does not occur during the heating and resulting production of aerosol. In other instances, there may be incidental pyrolysis, with production of oxidized or other thermal decomposition byproducts at levels that are insignificant relative to the primary constituents released by heating of the material.

[0105] As discussed herein, an aerosol -forming substrate is a material or combination of materials that may yield an aerosol. An aerosol relates to the matter generated or output by the devices disclosed, claimed, and equivalents thereof. The material may include a compoundAtty. Dkt. No. 24000NV-001126-WO-POA(e.g., nicotine, cannabinoid, cannabimimetic agent) that is released when the material is heated. In such an instance, an aerosol including the compound is produced when the material is heated. The heating may be below the ignition temperature so as to avoid a self-sustaining burning or a self-sustaining combustion of the material (i.e., in contrast to where a material is lit, such as lit-end cigarettes). It is understood that heating of a material below its ignition temperature may, in some circumstances, produce incidental and insubstantial levels of oxidized or other thermal decomposition byproducts. However, in some embodiments, the heating in aerosolgenerating devices is below the pyrolysis temperature of the material so as to produce an aerosol having no or insubstantial levels of thermal decomposition byproducts of the material. Thus, in an example embodiment, pyrolysis of the material does not occur during the heating and resulting production of aerosol. In other instances, there may be incidental pyrolysis, with production of oxidized or other thermal decomposition byproducts at levels that are insignificant relative to the primary constituents released by heating of the material.

[0106] The material(s) of the aerosol-forming substrate may include a fibrous material. For instance, the fibrous material may be a botanical material. The fibrous material is configured to release a compound when heated. The compound may be a naturally occurring constituent of the fibrous material. For instance, the fibrous material may be plant material such as tobacco, and the compound released may be nicotine. The term “tobacco” includes any tobacco plant material including tobacco leaf, tobacco plug, reconstituted tobacco, compressed tobacco, shaped tobacco, or powder tobacco, and combinations thereof from one or more species of tobacco plants, such as Nicotiana rustica and Nicotiana tabacum.

[0107] In some example embodiments, the tobacco material may include material from any member of the genus Nicotiana. In addition, the tobacco material may include a blend of two or more different tobacco varieties. Examples of suitable types of tobacco materials that may be used include, but are not limited to, flue-cured tobacco, Burley tobacco, Dark tobacco,Atty. Dkt. No. 24000NV-001126-WO-POAMaryland tobacco, Oriental tobacco, rare tobacco, specialty tobacco, blends thereof, and the like. The tobacco material may be provided in any suitable form, including, but not limited to, tobacco lamina, processed tobacco materials, such as volume expanded or puffed tobacco, processed tobacco stems, such as cut-rolled or cut-puffed stems, reconstituted tobacco materials, blends thereof, and the like. In some example embodiments, the tobacco material is in the form of a substantially dry tobacco mass. Furthermore, in some instances, the tobacco material may be mixed and / or combined with at least one of propylene glycol, glycerin, subcombinations thereof, or combinations thereof.

[0108] The compound in the generated aerosol may also be a naturally occurring constituent of a medicinal plant that has a medically-accepted physiological effect (e.g., therapeutic effect, prophylactic effect). For instance, the medicinal plant may be a cannabis plant or a cannabimimetic plant (i.e., a plant with similar pharmacological effects to those of cannabis). For a cannabis plant, the compound may be a cannabinoid. Cannabinoids interact with receptors in the body to produce a wide range of effects. As a result, cannabinoids have been used for a variety of medicinal purposes (e.g., treatment of pain, nausea, epilepsy, psychiatric disorders). The fibrous material may include the leaf and / or flower material from one or more species of cannabis plants such as Cannabis sativa, Cannabis indica, and Cannabis ruderalis. In some instances, the fibrous material is a mixture of 60-80% (e.g., 70%) Cannabis sativa and 20-40% (e.g., 30%) Cannabis indica. For a cannabimimetic plant, the compound may be a cannabimimetic agent. Cannabimimetic agents interact with receptors in the body to produce similar pharmacological effects as cannabinoids.

[0109] Examples of cannabinoids include tetrahydrocannabinolic acid (THCA), tetrahydrocannabinol (THC), cannabidiolic acid (CBDA), cannabidiol (CBD), cannabinol (CBN), cannabicyclol (CBL), cannabichromene (CBC), and cannabigerol (CBG). Tetrahydrocannabinolic acid (THCA) is a precursor of tetrahydrocannabinol (THC), whileAtty. Dkt. No. 24000NV-001126-WO-POAcannabidiolic acid (CBDA) is precursor of cannabidiol (CBD). Tetrahydrocannabinolic acid (THCA) and cannabidiolic acid (CBDA) may be converted to tetrahydrocannabinol (THC) and cannabidiol (CBD), respectively, via heating. In an example embodiment, heat from a heater (e.g., of the heating assembly 340 shown in FIG. 8) may cause decarboxylation so as to convert the tetrahydrocannabinolic acid (THCA) to tetrahydrocannabinol (THC), and / or to convert the cannabidiolic acid (CBDA) to cannabidiol (CBD).

[0110] In instances where both tetrahydrocannabinolic acid (THCA) and tetrahydrocannabinol (THC) are present, the decarboxylation and resulting conversion will cause a decrease in tetrahydrocannabinolic acid (THCA) and an increase in tetrahydrocannabinol (THC). At least 50% (e.g., at least 87%) of the tetrahydrocannabinolic acid (THCA) may be converted to tetrahydrocannabinol (THC) during the heating. Similarly, in instances where both cannabidiolic acid (CBDA) and cannabidiol (CBD) are present, the decarboxylation and resulting conversion will cause a decrease in cannabidiolic acid (CBDA) and an increase in cannabidiol (CBD). At least 50% (e.g., at least 87%) of the cannabidiolic acid (CBDA) may be converted to cannabidiol (CBD) during the heating.[OHl] Furthermore, the compound which is released may be or may additionally include a non-naturally occurring additive that is subsequently introduced into the fibrous material. In one instance, the fibrous material may include at least one of cotton, polyethylene, polyester, rayon, combinations thereof, or the like (e.g., in a form of a gauze). In another instance, the fibrous material may be a cellulose material (e.g., non-tobacco and / or non-cannabis material). In either instance, the compound introduced may include nicotine, cannabinoids, cannabimimetic agents, and / or flavorants. The flavorants may be from natural sources, such as plant extracts (e.g., tobacco extract, cannabis extract, cannabimimetic extract), and / or artificial sources. In yet another instance, when the fibrous material includes tobacco and / or cannabis, the compound may be or may additionally include one or more flavorants (e.g.,Atty. Dkt. No. 24000NV-001126-WO-POAmenthol, mint, vanilla). Thus, the compound within the aerosol -forming substrate may include naturally occurring constituents and / or non-naturally occurring additives. In this regard, it should be understood that existing levels of the naturally occurring constituents of the aerosolforming substrate may be increased through supplementation. For example, the existing levels of nicotine in a quantity of tobacco may be increased through supplementation with an extract containing nicotine. Similarly, the existing levels of one or more cannabinoids in a quantity of cannabis may be increased through supplementation with an extract containing such cannabinoids. Likewise, the existing levels of one or more cannabimimetic agents in a quantity of cannabimimetic material may be increased through supplementation with an extract containing such cannabimimetic agents.

[0112] FIG. l is a perspective view of an aerosol -forming substrate in loose form according to at least one example embodiment.

[0113] In at least one example embodiment, as shown in FIG. 1, an aerosol -forming substrate (also referred to as a “substrate” or “filler”) 100 includes a plurality of granules 102. Each of the granules 102 includes a plurality of particles and a binder. As will be discussed in greater detail below, each of the granules may further include an aerosol -former and / or additive (e.g., flavoring agent).

[0114] The plurality of particles may include a fibrous material and / or botanical material configured to release one or more constituents or compounds when heated. In at least one example embodiment, the plurality of particles include tobacco particles. In at least one example embodiment, the plurality of particles have an average size of greater than or equal to about 0.075 mm (e.g., greater than or equal to about 0.1 mm, greater than or equal to about 0.125 mm, greater than or equal to about 0.15 mm, greater than or equal to about 0.175 mm, greater than or equal to about 0.2 mm, or greater than or equal to about 0.225 mm). The plurality of particles may have an average size of less than or equal to about 0.25 mm (e.g., less than orAtty. Dkt. No. 24000NV-001126-WO-POAequal to about 0.225 mm, less than or equal to about 0.2 mm, less than or equal to about 0.175 mm, less than or equal to about 0.15 mm, less than or equal to about 0.125 mm, or less than or equal to about 0.1 mm).

[0115] The particles may be held together by the binder. In at least one example embodiment, the binder at least partially surrounds and / or encapsulates the particles. In at least one example embodiment, the binder includes cellulose, microcrystalline cellulose (MCC), hydroxypropylcellulose (HPC), methylcellulose (MC), ethyl cellulose (EC), hydroxypropylmethylcellulose (HPMC), sodium carboxymethylcellulose (NaCMC), starch, pregelatinized starch, gum acacia, maltodextrin, povidone (PVP), polyvinyl alcohol (PVA), polyvinylethylene glycol (PEG), polyvinyl alcohol graft polyethylene glycol copolymer (PVA-g-PEG), polymethacrylate, a sugar alcohol, or any combination thereof. In at least one example embodiment, the sugar alcohol includes ethylene glycol, glycerol, erythritol, threitol, arabitol, xylitol, ribitol, mannitol, sorbitol, galactitol, fucitol, iditol, inositol, volemitol, isomalt, maltitol, lactitol, maltotriitol, maltotetraitol, polyglycitol, or any combination thereof.

[0116] In at least one example embodiment, the granules 102 include the binder in an amount greater than or equal to about 1 weight percent (e.g., greater than or equal to about 2 weight percent, greater than or equal to about 3 weight percent, greater than or equal to about 4 weight percent, greater than or equal to about 5 weight percent, greater than or equal to about 6 weight percent, greater than or equal to about 7 weight percent, greater than or equal to about 8 weight percent, or greater than or equal to about 9 weight percent). The granules 102 may include the binder in an amount less than or equal to about 10 weight percent (e.g., less than or equal to about 9 weight percent, less than or equal to about 8 weight percent, less than or equal to about 7 weight percent, less than or equal to about 6 weight percent, less than or equal to about 5 weight percent, less than or equal to about 4 weight percent, less than or equal to about 3 weight percent, or less than or equal to about 2 weight percent). In at least one exampleAtty. Dkt. No. 24000NV-001126-WO-POAembodiment, the binder includes HPMC in an amount less than or equal to about 5 weight percent.

[0117] In at least one example embodiment, the granules 102 have a substantially spherical shape. The granules 102 may have an average diameter of greater than or equal to about 0.2 mm (e.g., greater than or equal to about 0.3 mm, greater than or equal to about 0.4 mm, greater than or equal to about 0.5 mm, greater than or equal to about 0.75 mm, greater than or equal to about 1 mm, greater than or equal to about 1.25 mm, greater than or equal to about 1.5 mm, greater than or equal to about 1.75 mm, greater than or equal to about 2 mm, or greater than or equal to about 2.25 mm). The average diameter of the granules 102 may be less than or equal to about 2.5 mm (e.g., less than or equal to about 2.25 mm, less than or equal to about 2 mm, less than or equal to about 1.75 mm, less than or equal to about 1.5 mm, less than or equal to about 1.25 mm, less than or equal to about 1 mm, less than or equal to about 0.75 mm, less than or equal to about 0.5 mm, less than or equal to about 0.4 mm, or less than or equal to about 0.3 mm).

[0118] The aerosol-forming substrate 100 may include an aerosol former. The aerosol former may be admixed and / or combined with the granules 102. As used herein, “admix,” means that two or more elements are combined together in a heterogeneous, inhomogeneous, or homogeneous manner. In at least one example embodiment, at least a portion of the aerosol former is adsorbed on and / or absorbed in the granules 102. The aerosol former may include propylene glycol, glycerol, butylene glycol, or any combination thereof.

[0119] In at least one example embodiment, the aerosol -forming substrate 100 includes the aerosol former in an amount greater than or equal to about 5 weight percent (e.g., greater than or equal to about 10 weight percent, greater than or equal to about 15 weight percent, greater than or equal to about 20 weight percent, greater than or equal to about 25 weight percent, greater than or equal to about 30 weight percent, greater than or equal to about 35 weightAtty. Dkt. No. 24000NV-001126-WO-POApercent, greater than or equal to about 40 weight percent, greater than or equal to about 45 weight percent, greater than or equal to about 50 weight percent, greater than or equal to about 55 weight percent, greater than or equal to about 60 weight percent, or greater than or equal to about 65 weight percent). The aerosol-forming substrate 100 may include the aerosol former in an amount less than or equal to about 70 weight percent (e.g., less than or equal to about 65 weight percent, less than or equal to about 60 weight percent, less than or equal to about 55 weight percent, less than or equal to about 50 weight percent, less than or equal to about 45 weight percent, less than or equal to about 40 weight percent, less than or equal to about 35 weight percent, less than or equal to about 30 weight percent, less than or equal to about 25 weight percent, less than or equal to about 20 weight percent, less than or equal to about 15 weight percent, or less than or equal to about 10 weight percent).

[0120] In at least one example embodiment, the aerosol -forming substrate 100 further includes a flavoring agent and / or antioxidant. In at least one example embodiment, the flavoring agent and / or antioxidant is admixed and / or combined with the granules 102. In at least one example embodiment, the flavoring agent and / or antioxidant is at least partially adsorbed on and / or absorbed in the granules 102. In at least one example embodiment, the flavoring agent and / or antioxidant is at least partially encapsulated by the binder. In at least one example embodiment, the flavoring agent is adsorbed on and / or absorbed in the plurality of particles. The flavoring agent may include menthol, peppermint, spearmint, wintergreen, menthol, cinnamon, chocolate, vanillin, licorice, clove, anise, sandalwood, geranium, rose oil, vanilla, lemon oil, cassia, fennel, ginger, ethylacetate, isoamylacetate, propylisobutyrate, isobutylbutyrate, ethylbutyrate, ethyl valerate, benzylformate, limonene, cymene, pinene, linalool, geraniol, citronellol, citral, orange oil, coriander oil, borneol, fruit extract, coffee, tea, cacao, mint, or any combination thereof. Additionally or alternatively, the flavoring agent mayAtty. Dkt. No. 24000NV-001126-WO-POAinclude a terpene, such as 8-myrcene, 8-caryophyllene, d-limonene, linalool, pulegone, 1,8-conele, a-pipene, a-perpineol, termineol-4-ol, p-cymene, or any combination thereof.

[0121] FIG. 2 is a perspective view of a consumable according to at least one example embodiment.

[0122] In at least one example embodiment, as shown in FIG. 2, a consumable or capsule 200 includes an outer housing or pod 202. The outer housing 202 may extend between a first end 204 and a second end 206. In at least one example embodiment, the first end 204 may have a flat end surface and the second end 206 may have a rounded end surface. In at least one example embodiment, the outer housing 202 is formed of a cellulose derivative. The cellulose derivative may include hydroxypropyl methylcellulose (HPMC), microcrystalline cellulose (MCC), nanocrystalline cellulose (NCC), or any combination thereof.

[0123] In at least one example embodiment, when the consumable 200 is in a device (see, e.g., device 500 of FIG. 5), the first end 204 is a top end and the second end 206 is a bottom end. The outer housing 202 may define an air inlet, such as a first plurality of perforations 208. The first plurality of perforations 208 may include between 2 and 100 perforations (e.g., about 5 to about 95, about 10 to about 90, about 15 to about 85, about 20 to about 80, about 25 to about 75, about 30 to about 70, about 35 to about 65, about 35 to about 60, or about 40 to about 55). The outer housing 202 defines an outer surface 210. The outer surface 210 may include a heating region 212, as will be described in greater detail below.

[0124] In at least one example embodiment, the consumable 200 includes greater than or equal to about 10 perforations (e.g., greater than or equal to about 20 perforations, greater than or equal to about 30 perforations, greater than or equal to about 40 perforations, greater than or equal to about 50 perforations, greater than or equal to about 60 perforations, greater than or equal to about 70 perforations, greater than or equal to about 80 perforations, greater than or equal to about 90 perforations, or greater than or equal to about 100 perforations). TheAtty. Dkt. No. 24000NV-001126-WO-POAconsumable 200 may include less than or equal to about 100 perforations (e.g., less than or equal to about 90 perforations, less than or equal to about 80 perforations, less than or equal to about 70 perforations, less than or equal to about 60 perforations, less than or equal to about 50 perforations, less than or equal to about 40 perforations, less than or equal to about 30 perforations, or less than or equal to about 20 perforations).

[0125] In at least one example embodiment, the perforations 208 have diameters of greater than or equal to about 0.05 mm (e.g., greater than or equal to about 0.075 mm, greater than or equal to about 0.1 mm, greater than or equal to about 0.125 mm, greater than or equal to about 0.15 mm, greater than or equal to about 0.175 mm, greater than or equal to about 0.2 mm, greater than or equal to about 0.225 mm, greater than or equal to about 0.25 mm, or greater than or equal to about 0.275 mm). The perforations 208 may have diameters of less than or equal to about 0.3 mm (e.g., less than or equal to about 0.275 mm, less than or equal to about 0.25 mm, less than or equal to about 0.225 mm, less than or equal to about 0.2 mm, less than or equal to about 0.175 mm, less than or equal to about 0.15 mm, less than or equal to about 0.125 mm, less than or equal to about 0.1 mm, or less than or equal to about 0.075 mm). In at least one example embodiment, the perforations 208 all have the same diameter.

[0126] FIG. 3A is a sectional view of the consumable of FIG. 2 taken at line III— III according to at least one example embodiment.

[0127] In at least one example embodiment, as shown in FIG. 3 A, the outer housing 202 of the consumable 200 defines a first interior region 300. The consumable 200 may, in at least one example embodiment, further include an inner housing or pod 302. The inner housing 302 may be in the first interior region 300. At least a portion of the inner housing 302 may be spaced apart from the outer housing 202 to define a first annular gap 304 therebetween.

[0128] In at least one example embodiment, the inner housing 302 includes a first portion 306, a second portion 308, and a third portion 310. The first portion 306 may be substantiallyAtty. Dkt. No. 24000NV-001126-WO-POAcylindrical and define a first diameter 312. The third portion 310 may be substantially cylindrical, conical, frusto-conical, or dart-shaped, for example, and define a second diameter 314 (e.g., at a largest point) that is smaller than the first diameter 312. The second portion 308 is between the first and third portions 306, 310 and may be tapered in diameter.

[0129] In at least one example embodiment, a diameter of the first diameter 312 may be greater than or equal to about 10 mm (e.g., greater than or equal to about 20 mm, greater than or equal to about 30 mm, greater than or equal to about 40 mm, or greater than or equal to about 50 mm. The first diameter 312 may be less than or equal to about 60 mm (e.g., less than or equal to about 50 mm, less than or equal to about 40 mm, less than or equal to about 30 mm, or less than or equal to about 20 mm). In at least one example embodiment, the second diameter 314 may be greater than or equal to about 1 mm (e.g., greater than or equal to about 2 mm, greater than or equal to about 4 mm, greater than or equal to about 6 mm, or greater than or equal to about 8 mm. The second diameter 314 may be less than or equal to about 10 mm (e.g., less than or equal to about 8 mm, less than or equal to about 6 mm, less than or equal to about 4 mm, or less than or equal to about 2 mm). A ratio of the first diameter 312 to the second diameter 314 may be greater than about 1 (e.g., greater than or equal to about 1.5, greater than or equal to about 2, greater than or equal to about 2.5, greater than or equal to about 3, greater than or equal to about 5, greater than or equal to about 10, greater than or equal to about 20, or greater than or equal to about 30). The ratio may be less than or equal to about 60 (e.g., less than or equal to about 30, less than or equal to about 20, less than or equal to about 10, less than or equal to about 5, less than or equal to about 3, less than or equal to about 2.5, less than or equal to about 2, or less than or equal to about 1.5).

[0130] The outer housing 202 and the inner housing 302 may cooperate to at least partially define a substrate region 316. In at least one example embodiment, the second and third portions 308, 310 of the inner housing 302 cooperate with a portion of the outer housing 202Atty. Dkt. No. 24000NV-001126-WO-POAto define the substrate region 316. In at least the example embodiment shown, the substrate region 316 defines a substantially annular shape. The substrate 100 may be contained within the substrate region 316. In at least one example embodiment, the aerosol-forming substrate 100 is loosely deposited in the substrate region 316. In at least one other example embodiment, a substrate is in a consolidated format.

[0131] In at least one example embodiment, the aerosol -forming substrate 100 in the substrate region 316 defines a bulk density. The bulk density may be greater than or equal to about 0.2 g / cm3(e.g., greater than or equal to about 0.3 g / cm3, greater than or equal to about 0.4 g / cm3, greater than or equal to about 0.5 g / cm3, greater than or equal to about 0.6 g / cm3, greater than or equal to about 0.7 g / cm3, greater than or equal to about 0.8 g / cm3, or greater than or equal to about 0.9 g / cm3). The bulk density may be less than or equal to about 1 g / cm3(e.g., less than or equal to about 0.9 g / cm3, less than or equal to about 0.8 g / cm3, less than or equal to about 0.7 g / cm3, less than or equal to about 0.6 g / cm3, less than or equal to about 0.5 g / cm3, less than or equal to about 0.4 g / cm3, or less than or equal to about 0.3 g / cm3).

[0132] In at least one example embodiment, the aerosol-forming substrate 100 is configured to have a pressure drop during use of greater than or equal to about 5 mmfkO (e.g., greater than or equal to about 10 mmfkO, greater than or equal to about 20 mmfhO, greater than or equal to about 30 mmfkO, greater than or equal to about 40 mmfkO, greater than or equal to about 50 mmfhO, greater than or equal to about 60 mmfkO, greater than or equal to about 70 mmfhO, greater than or equal to about 80 mmfhO, greater than or equal to about 90 mmfhO, greater than or equal to about 100 mmfkO, greater than or equal to about 110 mmfhO, or greater than or equal to about 120 mmfhO). The pressure drop may be less than or equal to about 130 mmfhO (e.g., less than or equal to about 120 mmfhO, less than or equal to about 110 mmfhO, less than or equal to about 100 mmfhO, less than or equal to about 90 mmfhO, less than or equal to about 80 mmfhO, less than or equal to about 70 mmfhO, less than orAtty. Dkt. No. 24000NV-001126-WO-POAequal to about 60 mrnEEO, less than or equal to about 50 mrnEEO, less than or equal to about 40 mrnEEO, less than or equal to about 30 mrnEEO, less than or equal to about 20 mrnEEO, or less than or equal to about 10 mrnEEO).

[0133] The inner housing 302 may define a second interior region 318. In at least one example embodiment, the inner housing 302 defines a second plurality of perforations 320 in the second portion 308. The second plurality of perforations 320 may provide fluid communication between the first and second interior regions 300, 318. The inner housing 302 may define a third plurality of perforations 322 in the third portion 310. The third plurality of perforations 322 may provide fluid communication between the first and second interior regions 300, 318. The perforations 208, 320, 322 may facilitate airflow into and through the consumable 200, as will be described in greater in the discussion accompanying FIG. 3B.

[0134] In at least one example embodiment, the consumable 200 further includes a flow restrictor 324. The flow restrictor 324 may be formed of polyethylene, polypropylene, polyethylene terephthalate (PET), acrylonitrile butadiene styrene (ABS), polystyrene, or any combination thereof. The flow restrictor 324 may be in the second interior region 318.

[0135] In at least one example embodiment, the flow restrictor 324 may be spaced apart a wall of the inner housing 302 to define a second annular gap 326 therebetween. In at least one example embodiment, the flow restrictor 324 includes one or more orifices 328 therein. Each of the orifices may have a diameter of greater than or equal to about 0.2 mm (e.g., greater than or equal to about 0.3 mm, greater than or equal to about 0.5 mm, greater than or equal to about 0.75 mm, greater than or equal to about 1 mm, or greater than or equal to about 1.25 mm). Each of the orifices 328 may have a diameter of less than or equal to about 1.5 mm (e.g., less than or equal to about 1.25 mm, less than or equal to about 1 mm, less than or equal to about 0.75 mm, less than or equal to about 0.5 mm, or less than or equal to about 0.3 mm). In at least one example embodiment, the flow restrictor 324 is sized and configured to establish a resistance-Atty. Dkt. No. 24000NV-001126-WO-POAto-draw (RTD) of greater than or equal to about 5 mmH20 (e.g., greater than or equal to about 10 mmThO, greater than or equal to about 20 mmH20, greater than or equal to about 30 mmThO, greater than or equal to about 40 mmThO, greater than or equal to about 50 mmThO, greater than or equal to about 60 mmH20, greater than or equal to about 70 mmH20, greater than or equal to about 80 mmThO, or greater than or equal to about 90 mmH20). The RTD may be less than or equal to about 100 mmThO (e.g., less than or equal to about 90 mmThO, less than or equal to about 80 mmThO, less than or equal to about 70 mmThO, less than or equal to about 60 mmfkO, less than or equal to about 50 mmfkO, less than or equal to about 40 mmfkO, less than or equal to about 30 mmThO, less than or equal to about 20 mmThO, or less than or equal to about 10 mmH20).

[0136] In at least one example embodiment, the consumable 200 further includes a filter 330. The filter 330 may be within the first interior region 300. The filter 330 may be at or near the first end 204 of the outer housing 202. The filter 330 may be formed of a plug of cellulose acetate tow. The filter 330 may define a length 332 of greater than or equal to about 5 mm (e.g., greater than or equal to about 7.5 mm, greater than or equal to about 10 mm, or greater than or equal to about 12.5 mm). The length 332 may be less than or equal to about 15 mm (e.g., less than or equal to about 12.5 mm, less than or equal to about 10 mm, or less than or equal to about 7.5 mm). The filter 330 may have a RTD of greater than or equal to about 5 mmfkO (e.g., greater than or equal to about 10 mmfkO, greater than or equal to about 15 mmH20, greater than or equal to about 20 mmH20, greater than or equal to about 25 mmH20, greater than or equal to about 30 mmH20, greater than or equal to about 35 mmfkO, greater than or equal to about 40 mmH20, or greater than or equal to about 45 mmfkO). The RTD of the filter 330 may be less than or equal to about 50 mmfkO (e.g., less than or equal to about 45 mmfkO, less than or equal to about 40 mmH20, less than or equal to about 35 mmThO, less than orAtty. Dkt. No. 24000NV-001126-WO-POAequal to about 30 mmFhO, less than or equal to about 25 mmFhO, less than or equal to about 20 mmFhO, less than or equal to about 15 mmFhO, or less than or equal to about 10 mmFhO).

[0137] FIG. 3B is a schematic view of the consumable of FIG. 3A illustrating airflow according to at least one example embodiment.

[0138] In at least one example embodiment, as shown in FIG. 3B, air enters the consumable 200 at the first perforations 208 along a first flow path 350. Once inside the consumable 200, air follows a second flow path 352 through the first annular gap 304 between the outer housing 202 and the inner housing 302. At this point, air is split into a third flow path 354 and a fourth flow path 356. The third flow path 354 is through the second perforations 320 and into the second interior region 318. The fourth flow path 356 is through the aerosol -forming substrate 100. When the air reaches the second end 206, it follows a fifth flow path 358 through the third perforations 322 into the second interior region 318, and then a sixth flow path 360 through the third portion 310 of the inner housing 302 and toward the second perforations 320. Past the second perforations 320, air follows a seventh flow path 362 through the second interior region 318 toward the flow restrictor 324. A portion of the air flows through the orifice 328 of the flow restrictor 324 along an eighth flow path 364. Another portion of the air flows around the flow restrictor 324 along a nineth flow path 366, and through the second annular gap 326 along a tenth flow path 368. Air continues out of the second interior region 318, into the first interior region 300, through the filter 330, and out of the first end 204 of the consumable 200 along an eleventh flow path 370.

[0139] FIG. 4 is a perspective view of the tobacco consumable of FIG. 2 including an external heater according to at least one example embodiment.

[0140] In at least one example embodiment, a consumable-heater assembly 400 includes the consumable 200 and a heater 402. The heater 402 may be a crucible heater. In at least the example embodiment shown, the heater 402 is an external heater. The heater 402 may beAtty. Dkt. No. 24000NV-001126-WO-POAconfigured to heat the outer surface 210 of the outer housing 202, such as in the heating region 212. Thus, the heater 402 may be configured to indirectly heat the aerosol-forming substrate 100 (shown in FIG. 3A) via heat transfer through the heating region 212 of the outer housing 202.

[0141] In at least one example embodiment, the heater 402 includes an open end 404 and a closed end 406. The heater 402 may be configured to receive at least a portion of the consumable 200 via the open end 404. The closed end 406 may be rounded and configured to fit snugly about the second end 206 of the consumable 200. In at least one example embodiment, at least a portion of the heating region 212 of the outer surface 210 is in direct contact with the heater 402. In other example embodiments, the heating region 212 of the outer surface 210 is not in direct contact with the heater 402.

[0142] FIG. 5 is a perspective view of a heated tobacco device including the tobacco consumable and heater of FIG. 4 according to at least one example embodiment.

[0143] In at least one example embodiment, as shown in FIG. 5, the consumable 200 may be configured to be used with a device 500. The device 500 may include a device body 502. The device body 502 may define an opening 504 into which the consumable 200 may be at least partially inserted. In at least one example embodiment, as shown, the device 500 may be free of a distinct mouthpiece, and the consumable 200 includes a mouthpiece. In at least one other example embodiment, the device 500 includes a mouthpiece and the consumable is fully received within the device 500.

[0144] In at least one example embodiment, the device 500 includes a single external heater (i.e., the heater 402). The device 500 may be free of an internal heater, such as a blade that extends into a substrate (e.g., at a radial center of the substrate). The heater 402 may be configured to provide a more uniform heating of the aerosol-forming substrate 100 (shown inAtty. Dkt. No. 24000NV-001126-WO-POAFIG. 2) compared to an internal blade heater, which may create a radial temperature gradient within a substrate. The heater 402 may be part of the device 500 or the consumable 200.

[0145] FIG. 6 is a schematic view of the device of FIG. 5 according to at least one example embodiment.

[0146] In at least one example embodiment, the device body 502 encases or houses the heater 402, a power source 600, and a processing or control circuity 602 within an interior region or chamber 604. The control circuitry 602 may be hardware including logic circuits; a hardware / software combination such as a processor executing software; or a combination thereof. For example, the control circuitry may include, but is not limited to, a central processing unit (CPU), an arithmetic logic unit (ALU), a digital signal processor, a microcomputer, a field programmable gate array (FPGA), a System-on-Chip (SoC), a programmable logic unit, a microprocessor, application-specific integrated circuit (ASIC), etc. The supply of current from the power source may be in response to a manual operation (e.g., button activation) or an automatic operation (e.g., puff-activation). In at least some example embodiments, the control circuity may further include a haptic motor that may be disposed on a side of the power source. In at least some example embodiments, the control circuitry 602 includes one or more sensors, such as a flow sensor, a temperature sensor, a sensor for motion detection, a biometric sensor, or any combination thereof.

[0147] The power source 600 may include one or more batteries (e.g., rechargeable dual battery arrangement, lithium-ion battery, and / or fuel cells).

[0001] It should be understood that the shape of the battery (or batteries) for the power supply 600 may vary. For example, the battery may be cylindrical, prismatic, disc-shaped, a pouch battery, or any other variation of battery shape known in the art. Additionally, it should be understood that the battery may be any of a variety of types. For example, in one embodiment, the battery may be a rechargeable battery (e.g., lithium-ion). In another embodiment, the battery may be a non-rechargeableAtty. Dkt. No. 24000NV-001126-WO-POAbattery (e.g., alkaline). In yet another embodiment, the battery may include silver oxide, carbon zinc, cadmium, nickel, or any another material known in the art. Furthermore, the battery may include a primary cell and / or a secondary cell. It will be understood by those of ordinary skill in the art that various changes in form and details of the battery may be made without departing from the spirit and the scope of the invention.

[0148] The heater 402 may be electrically connected to the power source. In at least one example embodiment, the heater 402 is configured to subject the consumable 200 to continuous heating or substantially continuous heating when the heater 402 is activated by supplying power from the power source 600 to the heater 402.

[0149] In at least one example embodiment, the aerosol-forming substrate 100 (shown in FIG. 3A) including the binder is configured to facilitate sustained release of constituents (e.g., nicotine). In at least one example embodiment, the aerosol-forming substrate 100 is configured to be constantly heated for a series of 10 puffs to release a total amount of released constituent (e.g., nicotine). The substrate 100 is configured to release less than about 70 weight percent of the total amount of released constituent during a first 5 puffs of the series of 10 puffs (e.g., less than or equal to about 65 weight percent, less than or equal to about 60 weight percent, less than or equal to about 57 weight percent, less than or equal to about 55 weight percent, less than or equal to about 53 weight percent, less than or equal to about 52 weight percent, or less than or equal to about 51 weight percent). In at least one example embodiment, the aerosolforming substrate 100 is configured to release constituent in an amount ranging from 35 weight percent of the total amount of released constituent during the first 5 puffs (e.g., greater than or equal to about 43 weight percent, greater than or equal to about 45 weight percent, greater than or equal to about 48 weight percent, or greater than or equal to about 50 weight percent).

[0150] FIG. 7 is a flowchart illustrating a method of manufacturing an aerosol -forming substrate according to at least one example embodiment.Atty. Dkt. No. 24000NV-001126-WO-POA

[0151] In at least one example embodiment, as shown in FIG. 7, a method of manufacturing a consumable (e.g., the consumable 200) generally includes optionally preparing a cut material at S700; preparing a powder from the cut material at S704; preparing wet granules from the powder at S708; preparing dry granules from the wet granules at S702; preparing an aerosolforming substrate from the dry granules at S716; and preparing a consumable including the aerosol-forming substrate at S720.

[0152] At S700, the method includes optionally preparing a cut material. In at least one example embodiment, S700 is performed using a tobacco cutter and / or a cutting mill. The cut material may be a cut tobacco material. The cut material may have an average length of greater than or equal to about 1 / 32 inch (e.g., greater than or equal to about 1 / 16 inch, greater than or equal to about 1 / 4 inch, or greater than or equal to about 1 / 2 inch). The length may be less than or equal to about 1 inch (e.g., less than or equal to about 1 / 2 inch, less than or equal to about 1 / 4 inch, less than or equal to about 1 / 16 inch). In other example embodiments, the cut material may be a cut non-tobacco material including any non-tobacco botanical.

[0153] At S704, the method includes preparing a powder from the cut material. In at least one example embodiment, the powder is a tobacco powder. The powder may have a size ranging from about 0.075 mm to about 0.125 mm, as described above in the discussion accompanying FIG. 1. Preparing the powder may include milling the cut material. In at least one example embodiment, S704 may include adding a flavorant to the cut material.

[0154] At S708, the method includes preparing wet granules (e.g., wet tobacco granules) from the powder. In at least one example embodiment, preparing the wet granules includes preparing a binder solution, forming an admixture of the binder solution and the particles, and preparing the wet granules from the admixture. Preparing the solution may include dissolving a binder in a solvent. The binder may include any of the binders described above in the discussion accompanying FIG. 1 (e.g., HMPC, MCC). The solvent may include water. In atAtty. Dkt. No. 24000NV-001126-WO-POAleast one example embodiment, preparing the admixture includes admixing the solution and the particles in a low-shear mixer.

[0155] In at least one example embodiment, preparing the wet granules from the admixture includes extruding the admixture, and then granulating the extrudate. In at least one example embodiment, the extrudate is in the form of a rod (e.g., a thing, spaghetti-like rod). In at least one other example embodiment, preparing the wet granules from the extrudate includes use of a multi -granulator with a dome die and / or side screens. In at least one example embodiment, S708 includes preparing wet granules having a desired shape, such as spheres, beads, and / or rods. Preparing wet granules having the desired shape may include marumerizing or spheronizing the wet granules. In at least one example embodiment, S708 includes preparing wet granules having a desired granule size.

[0156] At S712, the method includes preparing dry granules from the wet granules. Preparing dry granules includes reducing or removing solvent from the wet granules. As used herein “dry granules” refers to granules that contain less solvent than the wet granules.

[0157] In at least one example embodiment, preparing dry granules includes drying the wet granules in an oven at a desired (or alternatively, predetermined) temperature for a desired (or alternatively, predetermined) duration. The desired temperature may be greater than or equal to about 40°C (e.g., greater than or equal to about 50°C, greater than or equal to about 60°C, greater than or equal to about 70°C, or greater than or equal to about 80°C). The desired temperature may be less than or equal to about 90°C (e.g., less than or equal to about 80°C, less than or equal to about 70°C, less than or equal to about 60°C, or less than or equal to about 50°C). The desired duration may be greater than or equal to about 10 minutes (e.g., greater than or equal to about 20 minutes, greater than or equal to about 30 minutes, greater than or equal to about 1 hour, greater than or equal to about 5 hours, greater than or equal to about 10 hours, greater than or equal to about 15 hours, greater than or equal to about 20 hours, greater than orAtty. Dkt. No. 24000NV-001126-WO-POAequal to about 25 hours, greater than or equal to about 30 hours, greater than or equal to about 35 hours, greater than or equal to about 40 hours, greater than or equal to about 45 hours, greater than or equal to about 50 hours, or greater than or equal to about 55 hours). The desired duration may be less than or equal to about 60 hours (e.g., less than or equal to about 55 hours, less than or equal to about 50 hours, less than or equal to about 45 hours, less than or equal to about 40 hours, less than or equal to about 35 hours, less than or equal to about 30 hours, less than or equal to about 25 hours, less than or equal to about 20 hours, less than or equal to about 15 hours, less than or equal to about 10 hours, less than or equal to about 5 hours, less than or equal to about 1 hour, less than or equal to about 30 minutes, or less than or equal to about 20 minutes).

[0158] In at least one example embodiment, preparing dry granules includes fluidizing the wet granules in a fluidized bed vessel at a desired (or alternatively, predetermined) temperature for a desired (or alternatively, predetermined) duration. The desired temperature may be greater than or equal to about 30°C (e.g., greater than or equal to about 40°C, greater than or equal to about 50°C, greater than or equal to about 50°C, greater than or equal to about 50°C, greater than or equal to about 60°C, greater than or equal to about 70°C, or greater than or equal to about 80°C). The desired temperature may be less than or equal to about 90°C (e.g., less than or equal to about 80°C, less than or equal to about 70°C, less than or equal to about 60°C, less than or equal to about 50°C, or greater than or equal to about 40°C). The desired duration may be greater than or equal to about 5 minutes (e.g., greater than or equal to about 10 minutes, greater than or equal to about 15 minutes, greater than or equal to about 30 minutes, greater than or equal to about 45 minutes, greater than or equal to about 60 minutes, greater than or equal to about 75 minutes, greater than or equal to about 90 minutes, or greater than or equal to about 105 minutes). The desired duration may be less than or equal to about 120 minutes (2 hours) (e.g., less than or equal to about 105 minutes, less than or equal to about 90 minutes,Atty. Dkt. No. 24000NV-001126-WO-POAless than or equal to about 75 minutes, less than or equal to about 60 minutes, less than or equal to about 45 minutes, less than or equal to about 30 minutes, less than or equal to about 15 minutes, or less than or equal to about 10 minutes).

[0159] At S716, the method includes preparing an aerosol -forming substrate from the dry granules. Preparing the aerosol -forming substrate may include admixing and / or combining an aerosol former with the dry granules. In at least one example embodiment, admixing and / or combining is performed using a low-shear mixer or a high-shear mixer. In at least one example embodiment, S716 includes adsorbing and / or absorbing the aerosol former on / in the dry granules by allowing the admixture to equilibrate for a desired (or alternatively, predetermined) duration. The desired duration may be greater than or equal to about 2 hours (e.g., greater than or equal to about 6 hours, greater than or equal to about 6 hours, greater than or equal to about 1 day, greater than or equal to about 2 days, greater than or equal to about 3 days, greater than or equal to about 4 days, greater than or equal to about 5 days, greater than or equal to about 6 days, greater than or equal to about 7 days, greater than or equal to about 8 days, or greater than or equal to about 9 days). In at least one example embodiment, the desired duration is less than or equal to about 10 days (e.g., less than or equal to about 9 days, less than or equal to about 8 days, less than or equal to about 7 days, less than or equal to about 6 days, less than or equal to about 5 days, less than or equal to about 4 days, less than or equal to about 3 days, less than or equal to about 2 days, less than or equal to about 1 day, less than or equal to about 12 hours, or less than or equal to about 6 hours). In at least one example embodiment, S716 further includes combining the dry granules with a flavoring agent and / or other additives.

[0160] At S720, the method includes preparing a consumable including the aerosol-forming substrate. Preparing the consumable may include adding the aerosol-forming substrate to an annular space of a container (e.g., substrate region 316 shown in FIG. 3 A).Atty. Dkt. No. 24000NV-001126-WO-POA

[0161] Example embodiments have been disclosed herein, it should be understood that other variations may be possible. Such variations are not to be regarded as a departure from the spirit and scope of the present disclosure, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.

[0162] ILLUSTRATIVE EMBODIMENTS

[0163] Illustrative Embodiment 1. A method of making a consumable for a heated tobacco product, the method comprising: preparing a tobacco powder having a desired powder size; preparing wet tobacco granules by admixing the tobacco powder with a binder and a solvent; preparing tobacco granules by removing at least a portion of the solvent from the wet tobacco granules; preparing a filler by admixing the tobacco granules with an aerosol former; and preparing a consumable including the filler.

[0164] Illustrative Embodiment 2. The method of Illustrative Embodiment 1, wherein the preparing a consumable includes adding the filler to an annular space of a container such that the consumable includes the container having the filler therein, an outer surface of the container configured to be heated by an external heater.

[0165] Illustrative Embodiment 3. The method of Illustrative Embodiment 1, wherein the filler in the consumable has a bulk density ranging from 0.2 g / cm3to 1 g / cm3.

[0166] Illustrative Embodiment 4. The method of Illustrative Embodiment 1, wherein the filler is configured to be constantly heated for a series of 10 puffs to release a total amount of released nicotine, and the filler is configured to release less than 60 weight percent of the total amount of released nicotine during a first 5 puffs of the series of 10 puffs.

[0167] Illustrative Embodiment 5. The method of Illustrative Embodiment 4, wherein the filler is configured to release nicotine in an amount ranging from 35 weight percent to 60 weight percent of the total amount of released nicotine during the first 5 puffs.Atty. Dkt. No. 24000NV-001126-WO-POA

[0168] Illustrative Embodiment 6. The method of Illustrative Embodiment 1, wherein the desired powder size ranges from 0.075 mm to 0.25 mm.

[0169] Illustrative Embodiment 7. The method of Illustrative Embodiment 1, wherein the preparing tobacco granules includes, extruding the wet tobacco granules to form a tobacco extrudate, and granulating the tobacco extrudate to a desired tobacco granule diameter.

[0170] Illustrative Embodiment 8. The method of Illustrative Embodiment 7, wherein the desired granule diameter ranges from 0.2 mm to 2.5 mm.

[0171] Illustrative Embodiment 9. The method of Illustrative Embodiment 7, the tobacco extrudate is rod-shaped.

[0172] Illustrative Embodiment 10. The method of Illustrative Embodiment 7, wherein the granulating includes marumerizing the tobacco extrudate to form the tobacco granules, the tobacco granules being generally spherical.

[0173] Illustrative Embodiment 11. The method of Illustrative Embodiment 1, wherein the preparing the wet tobacco granules further includes admixing a flavoring agent with the tobacco powder, the solvent, and the binder.

[0174] Illustrative Embodiment 12. The method of Illustrative Embodiment 1, wherein the preparing the wet tobacco granules includes admixing the tobacco powder, the solvent, and the binder in a mixer.

[0175] Illustrative Embodiment 13. The method of Illustrative Embodiment 1, wherein the preparing the filler includes absorbing the aerosol former into the tobacco granules for a duration ranging from 2 hours to 10 days.

[0176] Illustrative Embodiment 14. The method of Illustrative Embodiment 1, wherein the preparing tobacco granules includes heating the wet tobacco granules in an oven for a duration ranging from 10 minutes to 60 hours, at a temperature ranging from 40°C to 90°C.Atty. Dkt. No. 24000NV-001126-WO-POA

[0177] Illustrative Embodiment 15. The method of Illustrative Embodiment 1, wherein the preparing tobacco granules includes fluidizing the wet tobacco granules in a fluidized bed for a duration ranging from 5 minutes to 2 hours at a temperature ranging from 30°C to 90°C.

[0178] Illustrative Embodiment 16. The method of Illustrative Embodiment 1, wherein the preparing the wet tobacco granules includes admixing the tobacco powder with the solvent and the binder, the binder including cellulose, microcrystalline cellulose, hydroxypropylcellulose, methylcellulose, ethyl cellulose, hydroxypropylmethylcellulose, sodium carboxymethylcellulose, starch, pregelatinized starch, gum acacia, maltodextrin, povidone, polyvinyl alcohol, polyvinylethylene glycol, polyvinyl alcohol graft polyethylene glycol copolymer, polymethacrylate, sugar alcohol, or any combination thereof.

[0179] Illustrative Embodiment 17. The method of Illustrative Embodiment 16, wherein the binder includes the hydroxypropylmethylcellulose.

[0180] Illustrative Embodiment 18. The method of Illustrative Embodiment 17, wherein tobacco granules include the hydroxypropylmethylcellulose at less than or equal to 5 weight percent.

[0181] Illustrative Embodiment 19. The method of Illustrative Embodiment 1, wherein the aerosol former includes propylene glycol, glycerol, butylene glycol, or any combination thereof.

[0182] Illustrative Embodiment 20. A method of making a consumable comprising: preparing wet granules by admixing a botanical powder with a binder and a solvent, the botanical powder having a size ranging from 0.075 mm to 0.25 mm; preparing dry granules by removing at least a portion of the solvent from the wet granules, the dry granules having a diameter ranging from about 0.2 mm to about 2.5 mm; preparing a substrate by admixing the dry granules with an aerosol former and an additive; and preparing a consumable including the substrate.Atty. Dkt. No. 24000NV-001126-WO-POA

[0183] Illustrative Embodiment 21. The method of Illustrative Embodiment 20, wherein the additive is a flavoring agent.

[0184] Illustrative Embodiment 22. A consumable for a heated tobacco product, the consumable comprising: a container defining an annular interior region, an outer surface of the container configured to be heated by an external heater; and a filler in the annular interior region, the filler including, tobacco granules, the tobacco granules in the annular interior region having a bulk density ranging from 0.2 g / cm3 to 1 g / cm3, the tobacco granules including, a binder including cellulose, microcrystalline cellulose, hydroxypropylcellulose, methylcellulose, ethyl cellulose, hydroxypropylmethylcellulose, sodium carboxymethylcellulose, starch, pregelatinized starch, gum acacia, maltodextrin, povidone, polyvinyl alcohol, polyvinylethylene glycol, polyvinyl alcohol graft polyethylene glycol copolymer, polymethacrylate, sugar alcohol, or any combination thereof, tobacco particles having a size ranging from 0.075 mm to 0.25 mm, and an aerosol former admixed with the tobacco granules.

[0185] Illustrative Embodiment 23. The consumable of Illustrative Embodiment 22, wherein the filler further includes an additive.

[0186] Illustrative Embodiment 24. The consumable of Illustrative Embodiment 23, wherein the additive includes a flavoring agent.

[0187] Illustrative Embodiment 25. The consumable of Illustrative Embodiment 22, wherein the binder includes hydroxypropylmethylcellulose.

[0188] Illustrative Embodiment 26. The consumable of Illustrative Embodiment 25, wherein the tobacco granules include the hydroxypropylmethylcellulose in an amount less than or equal to about 5 weight percent.

[0189] Illustrative Embodiment 27. The consumable of Illustrative Embodiment 22, wherein the binder includes the microcrystalline cellulose.Atty. Dkt. No. 24000NV-001126-WO-POA

[0190] Illustrative Embodiment 28. The consumable of Illustrative Embodiment 22, wherein the aerosol former includes propylene glycol, glycerol, butylene glycol, or any combination thereof.

[0191] Illustrative Embodiment 29. The consumable of Illustrative Embodiment 22, wherein the tobacco granules define a diameter ranging from 0.2 mm to 2.5 mm.

[0192] Illustrative Embodiment 30. A method of making a consumable for a heated tobacco product, the method comprising: admixing a tobacco powder with a binder and a solvent to form wet tobacco granules; removing at least a portion of the solvent from the wet tobacco granules to form tobacco granules; admixing the tobacco granules with an aerosol former to form a filler; and at least partially filling a portion of a consumable with the filler.

[0193] Illustrative Embodiment 31. The method of Illustrative Embodiment 30, wherein the at least partially filling a portion of a consumable includes adding the filler to an annular space of a container such that the consumable includes the container having the filler therein, an outer surface of the container configured to be heated by an external heater.

[0194] Illustrative Embodiment 32. The method of Illustrative Embodiment 30, wherein the at least partially filling a portion of a consumable includes adding the filler such that the filler has a bulk density ranging from 0.2 g / cm3to 1 g / cm3.

[0195] Illustrative Embodiment 33. The method of Illustrative Embodiment 30, wherein the tobacco powder has a desired powder size ranging from 0.075 mm to 0.25 mm.

[0196] Illustrative Embodiment 34. The method of Illustrative Embodiment 30, wherein the removing includes, extruding the wet tobacco granules to form a tobacco extrudate, and granulating the tobacco extrudate to a desired tobacco granule size.

[0197] Illustrative Embodiment 35. The method of Illustrative Embodiment 34, wherein the desired granule diameter ranges from 0.2 mm to 2.5 mm.Atty. Dkt. No. 24000NV-001126-WO-POA

[0198] Illustrative Embodiment 36. The method of Illustrative Embodiment 35, the tobacco extrudate is rod-shaped.

[0199] Illustrative Embodiment 37. The method of Illustrative Embodiment 34, wherein the granulating includes marumerizing the tobacco extrudate to form the tobacco granules, the tobacco granules being generally spherical.

[0200] Illustrative Embodiment 38. The method of Illustrative Embodiment 30, wherein the admixing a tobacco powder further includes admixing a flavoring agent with the tobacco powder, the solvent, and the binder.

[0201] Illustrative Embodiment 39. The method of Illustrative Embodiment 30, wherein the admixing a tobacco powder further includes admixing the tobacco powder, the solvent, and the binder in a mixer.

[0202] Illustrative Embodiment 40. The method of Illustrative Embodiment 30. wherein the admixing the tobacco granules includes absorbing the aerosol former into the tobacco granules for a duration ranging from 2 hours to 10 days.

[0203] Illustrative Embodiment 41. The method of Illustrative Embodiment 30, wherein the removing includes heating the wet tobacco granules in an oven for a duration ranging from 10 minutes to 60 hours, at a temperature ranging from 40°C to 90°C.

[0204] Illustrative Embodiment 42. The method of Illustrative Embodiment 30, wherein the removing includes fluidizing the wet tobacco granules in a fluidized bed for a duration ranging from 5 minutes to 2 hours at a temperature ranging from 30°C to 90°C.

[0205] Illustrative Embodiment 43. The method of Illustrative Embodiment 30, wherein the admixing a tobacco powder includes admixing the tobacco powder with the solvent and the binder, the binder including cellulose, microcrystalline cellulose, hydroxypropylcellulose, methylcellulose, ethyl cellulose, hydroxypropylmethylcellulose, sodium carboxymethylcellulose, starch, pregelatinized starch, gum acacia, maltodextrin, povidone,Atty. Dkt. No. 24000NV-001126-WO-POApolyvinyl alcohol, polyvinylethylene glycol, polyvinyl alcohol graft polyethylene glycol copolymer, polymethacrylate, sugar alcohol, or any combination thereof.

[0206] Illustrative Embodiment 44. The method of Illustrative Embodiment 43, wherein the binder includes the hydroxypropylmethylcellulose.

[0207] Illustrative Embodiment 45. The method of Illustrative Embodiment 44, wherein tobacco granules include the hydroxypropylmethylcellulose at less than or equal to 5 weight percent.

[0208] Illustrative Embodiment 46. The method of Illustrative Embodiment 30, wherein the aerosol former includes propylene glycol, glycerol, butylene glycol, or any combination thereof.

[0209] Illustrative Embodiment 47. A heated tobacco product comprising: a device body including, a housing defining a chamber, a heater, and a power supply configured to supply power to the heater; and a consumable configured to be at least partially received in the chamber, the consumable including, a container defining an annular interior region, an outer surface of the container configured to be heated by the heater; and a filler in the annular interior region, the filler including, tobacco granules, the tobacco granules in the annular interior region having a bulk density ranging from 0.2 g / cm3 to 1 g / cm3, the tobacco granules including, a binder including cellulose, microcrystalline cellulose, hydroxypropylcellulose, methylcellulose, ethyl cellulose, hydroxypropylmethylcellulose, sodium carboxymethylcellulose, starch, pregelatinized starch, gum acacia, maltodextrin, povidone, polyvinyl alcohol, polyvinylethylene glycol, polyvinyl alcohol graft polyethylene glycol copolymer, polymethacrylate, sugar alcohol, or any combination thereof, tobacco particles having a size ranging from 0.075 mm to 0.25 mm, and an aerosol former admixed with the tobacco granules.Atty. Dkt. No. 24000NV-001126-WO-POA

[0210] Illustrative Embodiment 48. The heated tobacco product of Illustrative Embodiment 47, wherein the filler further includes an additive.

[0211] Illustrative Embodiment 49. The heated tobacco product of Illustrative Embodiment 48, wherein the additive includes a flavoring agent.

[0212] Illustrative Embodiment 50. The heated tobacco product of Illustrative Embodiment 47, wherein the binder includes hydroxypropylmethylcellulose.

[0213] Illustrative Embodiment 51. The heated tobacco product of Illustrative Embodiment 50, wherein the tobacco granules include the hydroxypropylmethylcellulose in an amount less than or equal to about 5 weight percent.

[0214] Illustrative Embodiment 52. The heated tobacco product of Illustrative Embodiment 47, wherein the binder includes the microcrystalline cellulose.

[0215] Illustrative Embodiment 53. The heated tobacco product of Illustrative Embodiment 47, wherein the aerosol former includes propylene glycol, glycerol, butylene glycol, or any combination thereof.

[0216] Illustrative Embodiment 54. The heated tobacco product of Illustrative Embodiment 47, wherein the tobacco granules define a diameter ranging from 0.2 mm to 2.5 mm.

[0217] Illustrative Embodiment 55. A method of making a filler for a heated tobacco product, the method comprising: preparing a tobacco powder having a desired powder size; preparing wet tobacco granules by admixing the tobacco powder with a binder and a solvent; preparing tobacco granules by removing at least a portion of the solvent from the wet tobacco granules; and preparing a filler by admixing the tobacco granules with an aerosol former.

[0218] Illustrative Embodiment 56. The method of Illustrative Embodiment 55, wherein the filler is configured to be constantly heated for a series of 10 puffs to release a total amount of released nicotine, and the filler is configured to release less than 60 weight percent of the total amount of released nicotine during a first 5 puffs of the series of 10 puffs.Atty. Dkt. No. 24000NV-001126-WO-POA

[0219] Illustrative Embodiment 57. The method of Illustrative Embodiment 56, wherein the filler is configured to release nicotine in an amount ranging from 35 weight percent to 60 weight percent of the total amount of released nicotine during the first 5 puffs.

[0220] Illustrative Embodiment 58. The method of Illustrative Embodiment 55, wherein the desired powder size ranges from 0.075 mm to 0.25 mm.

[0221] Illustrative Embodiment 59. The method of Illustrative Embodiment 55, wherein the preparing tobacco granules includes, extruding the wet tobacco granules to form a tobacco extrudate, and granulating the tobacco extrudate to a desired tobacco granule diameter.

[0222] Illustrative Embodiment 60. The method of Illustrative Embodiment 59, wherein the desired granule diameter ranges from 0.2 mm to 2.5 mm.

[0223] Illustrative Embodiment 61. The method of Illustrative Embodiment 59, the tobacco extrudate is rod-shaped.

[0224] Illustrative Embodiment 62. The method of Illustrative Embodiment 59, wherein the granulating includes marumerizing the tobacco extrudate to form the tobacco granules, the tobacco granules being generally spherical.

[0225] Illustrative Embodiment 63. The method of Illustrative Embodiment 55, wherein the preparing the wet tobacco granules further includes admixing a flavoring agent with the tobacco powder, the solvent, and the binder.

[0226] Illustrative Embodiment 64. The method of Illustrative Embodiment 55, wherein the preparing the wet tobacco granules includes admixing the tobacco powder, the solvent, and the binder in a mixer.

[0227] Illustrative Embodiment 65. The method of Illustrative Embodiment 55, wherein the preparing the filler includes absorbing the aerosol former into the tobacco granules for a duration ranging from 2 hours to 10 days.Atty. Dkt. No. 24000NV-001126-WO-POA

[0228] Illustrative Embodiment 66. The method of Illustrative Embodiment 55, wherein the preparing tobacco granules includes heating the wet tobacco granules in an oven for a duration ranging from 10 minutes to 60 hours, at a temperature ranging from 40°C to 90°C.

[0229] Illustrative Embodiment 67. The method of Illustrative Embodiment 55, wherein the preparing tobacco granules includes fluidizing the wet tobacco granules in a fluidized bed for a duration ranging from 5 minutes to 2 hours at a temperature ranging from 30°C to 90°C.

[0230] Illustrative Embodiment 68. The method of Illustrative Embodiment 55, wherein the preparing the wet tobacco granules includes admixing the tobacco powder with the solvent and the binder, the binder including cellulose, microcrystalline cellulose, hydroxypropylcellulose, methylcellulose, ethyl cellulose, hydroxypropylmethylcellulose, sodium carboxymethylcellulose, starch, pregelatinized starch, gum acacia, maltodextrin, povidone, polyvinyl alcohol, polyvinylethylene glycol, polyvinyl alcohol graft polyethylene glycol copolymer, polymethacrylate, sugar alcohol, or any combination thereof.

[0231] Illustrative Embodiment 69. The method of Illustrative Embodiment 68, wherein the binder includes the hydroxypropylmethylcellulose.

[0232] Illustrative Embodiment 70. The method of Illustrative Embodiment 69, wherein tobacco granules include the hydroxypropylmethylcellulose at less than or equal to 5 weight percent.

[0233] Illustrative Embodiment 71. The method of Illustrative Embodiment 55, wherein the aerosol former includes propylene glycol, glycerol, butylene glycol, or any combination thereof.

[0234] Illustrative Embodiment 72. A method of making a composition comprising: preparing wet granules by admixing a botanical powder with a binder and a solvent, the botanical powder having a size ranging from 0.075 mm to 0.25 mm; preparing dry granules by removing at least a portion of the solvent from the wet granules, the dry granules having aAtty. Dkt. No. 24000NV-001126-WO-POAdiameter ranging from about 0.2 mm to about 2.5 mm; and preparing a composition by admixing the dry granules with an aerosol former and an additive.

[0235] Illustrative Embodiment 73. The method of Illustrative Embodiment 72, wherein the additive is a flavoring agent.

Claims

Atty. Dkt. No. 24000NV-001126-WO-POACLAIMS1. A method of making a consumable for a heated tobacco product, the method comprising:preparing a tobacco powder having a desired powder size;preparing wet tobacco granules by admixing the tobacco powder with a binder and a solvent;preparing tobacco granules by removing at least a portion of the solvent from the wet tobacco granules;preparing a filler by admixing the tobacco granules with an aerosol former; and preparing a consumable including the filler.

2. The method of claim 1, wherein the preparing a consumable includes adding the filler to an annular space of a container such that the consumable includes the container having the filler therein, an outer surface of the container configured to be heated by an external heater.

3. The method of claim 1, wherein the filler in the consumable has a bulk density ranging from 0.2 g / cm3to 1 g / cm3.

4. The method of claim 1, wherein the desired powder size ranges from 0.075 mm to 0.25 mm.

5. The method of claim 1, wherein the preparing tobacco granules includes, extruding the wet tobacco granules to form a tobacco extrudate, andgranulating the tobacco extrudate to a desired tobacco granule diameter.Atty. Dkt. No. 24000NV-001126-WO-POA6. The method of claim 5, wherein the desired tobacco granule diameter ranges from 0.2 mm to 2.5 mm.

7. The method of claim 5, the tobacco extrudate is rod-shaped.

8. The method of claim 5, wherein the granulating includes marumerizing the tobacco extrudate to form the tobacco granules, the tobacco granules being generally spherical.

9. The method of claim 1, wherein the preparing the wet tobacco granules further includes admixing a flavoring agent with the tobacco powder, the solvent, and the binder.

10. The method of claim 1, wherein the preparing the wet tobacco granules includes admixing the tobacco powder, the solvent, and the binder in a mixer.

11. The method of claim 1, wherein the preparing the filler includes absorbing the aerosol former into the tobacco granules for a duration ranging from 2 hours to 10 days.

12. The method of claim 1, wherein the preparing tobacco granules includes heating the wet tobacco granules in an oven for a duration ranging from 10 minutes to 60 hours, at a temperature ranging from 40°C to 90°C.

13. The method of claim 1, wherein the preparing tobacco granules includes fluidizing the wet tobacco granules in a fluidized bed for a duration ranging from 5 minutes to 2 hours at a temperature ranging from 30°C to 90°C.Atty. Dkt. No. 24000NV-001126-WO-POA14. The method of claim 1, wherein the preparing the wet tobacco granules includes admixing the tobacco powder with the solvent and the binder, the binder including cellulose, microcrystalline cellulose, hydroxypropylcellulose, methylcellulose, ethyl cellulose, hydroxypropylmethylcellulose, sodium carboxymethylcellulose, starch, pregelatinized starch, gum acacia, maltodextrin, povidone, polyvinyl alcohol, polyvinylethylene glycol, polyvinyl alcohol graft polyethylene glycol copolymer, polymethacrylate, sugar alcohol, or any combination thereof.

15. The method of claim 14, wherein the binder includes the hydroxypropylmethylcellulose.

16. The method of claim 15, wherein tobacco granules include the hydroxypropylmethylcellulose at less than or equal to 5 weight percent.

17. The method of claim 1, wherein the aerosol former includes propylene glycol, glycerol, butylene glycol, or any combination thereof.

18. A method of making a consumable comprising:preparing wet granules by admixing a botanical powder with a binder and a solvent, the botanical powder having a size ranging from 0.075 mm to 0.25 mm;preparing dry granules by removing at least a portion of the solvent from the wet granules, the dry granules having a diameter ranging from about 0.2 mm to about 2.5 mm; preparing a substrate by admixing the dry granules with an aerosol former and an additive; andpreparing a consumable including the substrate.Atty. Dkt. No. 24000NV-001126-WO-POA19. The method of claim 18, wherein the additive is a flavoring agent.

20. A consumable for a heated tobacco product, the consumable comprising:a container defining an annular interior region, an outer surface of the container configured to be heated by an external heater; anda filler in the annular interior region, the filler including,tobacco granules, the tobacco granules in the annular interior region having a bulk density ranging from 0.2 g / cm3to 1 g / cm3, the tobacco granules including,a binder including cellulose, microcrystalline cellulose, hydroxypropylcellulose, methylcellulose, ethyl cellulose, hydroxypropylmethylcellulose, sodium carboxymethylcellulose, starch, pregelatinized starch, gum acacia, maltodextrin, povidone, polyvinyl alcohol, polyvinylethylene glycol, polyvinyl alcohol graft polyethylene glycol copolymer, polymethacrylate, sugar alcohol, or any combination thereof, tobacco particles having a size ranging from 0.075 mm to 0.25 mm, and an aerosol former admixed with the tobacco granules.

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