RU2803182C2 - Method for composition of aerosol precursor for aerosol delivery device - Google Patents

Abstract

FIELD: tobacco industry.

SUBSTANCE: invention relates to a method for the production of an aerosol precursor composition. First, an aqueous solution is obtained, containing one or more organic acids and nicotine in water. Then, the specified aqueous solution is combined with one or more vapor generators to obtain an aerosol precursor composition. After combination, the aerosol precursor composition is included in an aerosol delivery device, wherein the aqueous solution contains at least one of organic acids in the given amount, and the aerosol precursor composition contains at least one organic acid in the final amount, which is 75% or more of the given amount.

EFFECT: disclosed method leads to improved control of a composition and characteristics of the resulting aerosol precursor composition.

13 cl, 3 dwg

Description

TECHNICAL FIELD

[0001] The present invention relates to aerosol delivery devices such as smoking articles, and more particularly to aerosol delivery devices that can use electrically generated heat to produce an aerosol (eg, smoking articles commonly referred to as electronic cigarettes). Smoking articles may be configured to heat an aerosol precursor, which may include materials that may be made or derived from tobacco, or otherwise include tobacco, which precursor is capable of forming an inhalable substance for human consumption.

BACKGROUND OF THE ART

[0002] Over the years, many smoking devices have been proposed as an improvement or alternative to smoking products that require combustion of tobacco for use. It is understood that many of these devices have been designed to provide the sensations associated with smoking cigarettes, cigars or pipes, but without delivering the significant amounts of incomplete combustion and pyrolysis products that result from the combustion of tobacco. To this end, a variety of smoking products, flavor generators and medicinal inhalers have been proposed that use electrical energy to vaporize or heat volatile material or attempt to provide the sensation of smoking cigarettes, cigars or pipes without substantially burning the tobacco. See, for example, the various alternative smoking articles, aerosol delivery devices, and heat generating sources set forth in the prior art as described in U.S. Patent Nos. 7,726,320 to Robinson et al. and U.S. Patent No. 8,881,737 to Collett et al., which are incorporated into this document by reference. Also see, for example, the various types of smoking articles, aerosol delivery devices, and electrically powered heat generating sources referenced by trademark and commercial information in US Patent Publication No. 2015/0216232 by Bless et al., which incorporated herein by reference. Additionally, various types of electrical aerosol and vapor delivery devices have also been proposed in US Patent Application Publications No. 2014/0096781 to Sears et al., No. 2014/0283859 to Minskoff et al., No. 2015/0335070 to Sears et al. ., No. 2015/0335071 by Brinkley et al., No. 2016/0007651 by Ampolini et al., and 2016/0050975 by Worm et al., all of which are incorporated herein by reference. Some of these alternative smoking products, such as aerosol delivery devices, have replaceable cartridges or refillable containers of aerosol precursor (eg, vape juice, e-liquid, and e-juice).

[0003] It is preferred to provide alternative methods for producing the aerosol precursor of such aerosol delivery devices.

DISCLOSURE OF THE INVENTION

[0004] The present invention relates to methods for preparing aerosol precursor compositions, for example, for use in aerosol delivery devices such as electronic cigarettes, and to compositions provided by such methods. As will be fully described later in this document, such methods provide certain advantages, such as component stability.

[0005] In one aspect, there is provided a method for preparing an aerosol precursor composition, comprising: providing an aqueous solution containing one or more organic acids and nicotine in water; and then combining this aqueous solution with one or more vapor formers to form an aerosol precursor composition.

[0006] In some embodiments, the aqueous solution contains at least one of one or more organic acids in a predetermined amount, and the aerosol precursor composition contains at least one of one or more organic acids in a final amount that is close to the predetermined amount. For example, in certain embodiments, the final amount is about 75% or more of the target amount, about 80% or more of the target amount, or about 90% or more of the target amount. In some embodiments, the aqueous solution contains one or more organic acids in a predetermined amount, wherein the aerosol precursor composition contains one or more organic acids in a final amount that is close to the predetermined amount. For example, in certain embodiments, the final amount is about 75% or more of the target amount, about 80% or more of the target amount, or about 90% or more of the target amount.

[0007] In some embodiments, one or more organic acids are selected from the group consisting of levulinic acid, succinic acid, lactic acid, pyruvic acid, benzoic acid, fumaric acid, and combinations thereof. One or more vapor formers may be, for example, polyols. Such polyols may include, without limitation, propylene glycol, glycerin, and combinations thereof.

[0008] In certain embodiments, the disclosed method may be performed such that the preparation and combining steps are performed in the absence of added heat. In some embodiments, to produce an aqueous solution, the preparation step includes a treatment selected from heating, shaking, stirring, and combinations thereof. The disclosed method may further include adding additional components before or after the combining step. Such additional components may include, without limitation, flavoring agents.

[0009] In some embodiments, the method further includes incorporating the aerosol precursor composition into an aerosol delivery device, such as an electronic cigarette. Also disclosed herein are compositions provided in accordance with the disclosed methods, as well as aerosol delivery devices containing such compositions.

[00010] Certain specific implementations are as follows:

[00011] Embodiment 1: A method for producing an aerosol precursor composition, comprising: producing an aqueous solution containing one or more organic acids and nicotine in water; and combining said aqueous solution with one or more vapor formers to form an aerosol precursor composition.

[00012] Embodiment 2: The method of the preceding embodiment, wherein the aqueous solution contains at least one of one or more organic acids in a predetermined amount, and the aerosol precursor composition contains at least one of one or more organic acids in a predetermined amount , which is close to the specified quantity.

[00013] Embodiment 3: The method of the preceding embodiment wherein the final amount is about 75% or more of the target amount.

[00014] Embodiment 4: The method of the preceding embodiment wherein the final amount is about 80% or more of the target amount.

[00015] Embodiment 5: The method of the preceding embodiment, wherein the final amount is about 90% or more of the predetermined amount.

[00016] Embodiment 6: The method of any of the preceding embodiments, wherein the aqueous solution contains one or more organic acids in a predetermined amount, and the aerosol precursor composition contains one or more organic acids in a final amount that is close to the predetermined amount.

[00017] Embodiment 7: The method of the preceding embodiment, wherein the final amount is about 75% or more of the target amount.

[00018] Embodiment 8: The method of the preceding embodiment, wherein the final amount is about 80% or more of the target amount.

[00019] Embodiment 9: The method of the preceding embodiment, wherein the final amount is about 90% or more of the target amount.

[00020] Embodiment 10: The method of any of the preceding embodiments, wherein the one or more organic acids are selected from the group consisting of levulinic acid, succinic acid, lactic acid, pyruvic acid, benzoic acid, fumaric acid, and combinations thereof.

[00021] Embodiment 11: The method of any preceding embodiment wherein the one or more vapor formers are polyols.

[00022] Embodiment 12: The method as in any of the preceding embodiments, wherein the preparation and combining steps are performed in the absence of added heat.

[00023] Embodiment 13: The method of any of the preceding embodiments, wherein, to obtain an aqueous solution, the preparation step includes a treatment selected from heating, shaking, stirring, and combinations thereof.

[00024] Embodiment 14: The method as in any preceding embodiment, further comprising adding additional components before or after the combining step.

[00025] Embodiment 15: The method of the preceding embodiment wherein the additional components are flavoring agents.

[00026] Embodiment 16: The method of any preceding embodiment, further comprising including the aerosol precursor composition in the aerosol delivery device.

[00027] These and other features, aspects and advantages of the disclosure of the present invention will become apparent upon reading the following detailed description taken in conjunction with the accompanying drawings, which are briefly described below. The present invention includes any combination of two, three, four or more of the above embodiments, as well as combinations of two, three, four or more features or elements set forth herein, whether or not such features or elements are combined in expressly in the description of a particular embodiment herein. This invention is intended to be read as a whole, such that any individual features or elements of the disclosed invention in any of its aspects and embodiments are to be considered combinable unless the context clearly dictates otherwise. Other aspects and advantages of the present invention will become apparent from the following.

BRIEF DESCRIPTION OF THE DRAWINGS

[00028] Having therefore described the present invention in the foregoing general terms, reference is made below to the accompanying drawings, which are not necessarily to scale, in which:

[00029] in FIG. 1 is a flow diagram of exemplary method steps of an embodiment of the present disclosure;

[00030] in FIG. 2 is a side view of an aerosol delivery device including a cartridge coupled to a control housing according to an example embodiment of the disclosure of the present invention; And

[00031] in FIG. 3 is a partial cross-sectional view of an aerosol delivery device according to various example implementations.

IMPLEMENTATION OF THE INVENTION

[00032] The present invention is described in more detail below with reference to examples of its implementations. These exemplary embodiments are described in such a manner that the disclosure will thoroughly, completely and completely convey the scope of the invention to one skilled in the art. In fact, the present invention can be implemented in many different forms and should not be construed as limited to the embodiments given herein; rather, these embodiments are provided to ensure that the present invention complies with applicable legal requirements. In this specification and in the accompanying claims, grammatical construction indicating that an element is in the singular also implies the plural unless the context of the invention clearly dictates otherwise.

[00033] As described below, the present invention relates to methods for preparing aerosol precursor mixtures for use in aerosol delivery systems. In particular, such methods involve combining certain components to be included in the aerosol precursor mixture in a specific order to produce an aerosol precursor that has various desired characteristics, for example, concentration of ingredients corresponding to target concentrations and good storage stability. In particular, the disclosed methods can provide a relatively high degree of control over the composition and characteristics of aerosol precursor mixtures.

[00034] In general, aerosol precursors include a combination or mixture of various ingredients (ie, components). The selection of specific aerosol precursor components and the relative amounts of these components used can be varied to control the overall chemistry of the bulk aerosol stream produced by the atomizer of the aerosol delivery device.

[00035] In some embodiments, the aerosol precursor composition may produce a visible aerosol when sufficiently heated (and, if necessary, cooled with air), and the aerosol precursor composition may produce an aerosol that is considered "smoke-like." In other embodiments, the aerosol precursor composition may produce an aerosol that may be substantially invisible but may be recognizable as present by other characteristics such as aroma or texture. Thus, the nature of the resulting aerosol may vary depending on the specific components of the aerosol precursor composition. The aerosol precursor composition may be chemically simple compared to the chemical nature of the smoke produced by burning tobacco.

[00036] Of particular interest are aerosol precursors, which can generally be characterized as being generally liquid in nature. For example, typical liquid aerosol precursors may be in the form of liquid solutions, mixtures of miscible components, or liquids containing suspended or dispersed components that can evaporate when exposed to heat under the conditions encountered when using aerosol delivery devices and, therefore, are capable of releasing vapors and aerosols that can be inhaled.

[00037] Aerosol precursors typically include a so-called "aerosol former" component. Such materials have the ability to produce visible aerosols when evaporated under the influence of heat under the conditions encountered during normal use of the atomizers of the present invention. Such aerosol-forming materials include various polyols/polyalcohols (eg, glycerin, propylene glycol, or mixtures thereof). Many embodiments of the present disclosure include aerosol precursor components that can be characterized as water, moisture, or an aqueous liquid. Under normal use of certain aerosol delivery devices, water included in the devices may evaporate to release components of the generated aerosol. Thus, for purposes of the present disclosure, the water present in the aerosol precursor may be considered an aerosol-forming material. For example, aerosol precursor compositions may include mixtures of glycerin and water, mixtures of propylene glycol and water, mixtures of propylene glycol and glycerin, or mixtures of propylene glycol, glycerin and water.

[00038] The aerosol precursor compositions may further contain one or more fragrances, medications, or other respirable materials. A variety of flavoring agents or materials that alter the sensory character or nature of the aerosol main stream drawn in may be included as aerosol precursor components. Flavoring agents may be added, for example, to change the taste, aroma and/or organoleptic properties of the aerosol. Certain flavoring agents may be provided from sources other than tobacco. Flavoring agents may be natural or artificial in nature and may be used in the form of concentrates or flavor additives.

[00039] Examples of flavoring agents include vanillin, ethyl vanillin, cream, tea, coffee, fruit (e.g., apple, cherry, strawberry, peach, and citrus flavors including lime and lemon), floral flavors, spicy flavors, maple, menthol, mint, peppermint, spearmint, wintergreen, nutmeg, cloves, lavender, cardamom, ginger, honey, anise, sage, cinnamon, sandalwood, jasmine, cascarrolle, cocoa, licorice, menthol and flavorings and additives of the type and character traditionally used for flavoring cigarette tobacco, cigar tobacco and pipe tobacco. Examples of plant-derived compositions that can be used are disclosed in US Application No. 12/971,746 to Dube et al. and US Application No. 13/015,744 to Dube et al., the disclosures of which are incorporated herein by reference in their entirety. In addition, syrups such as high fructose corn syrup can be used. Certain flavoring agents may be included in the aerosol-forming materials prior to formulation of the final aerosol precursor mixture (e.g., certain water-soluble flavoring agents may be included in water, menthol may be included in propylene glycol, and certain complex flavoring agents may be included in propylene glycol ).

[00040] Flavoring agents may also include acidic or basic characteristics (eg, organic acids, ammonium salts, or organic amines). Organic acids, in particular, can be included in the aerosol precursor to provide desired changes in the aroma, feel or organoleptic properties of medications, such as nicotine, which can be combined with the aerosol precursor. For example, organic acids such as levulinic acid, succinic acid, lactic acid, pyruvic acid, benzoic acid and/or fumaric acid can be included in the nicotine aerosol precursor in amounts up to equimolar (based on total organic acid content) with nicotine. Any combination of organic acids may be used. For example, the aerosol precursor may include from about 0.1 to about 0.5 moles of levulinic acid per mole of nicotine, from about 0.1 to about 0.5 moles of pyruvic acid per mole of nicotine, from about 0.1 to about 0.5 moles of lactic acid per mole of nicotine, or a combination thereof, up to a concentration at which the total amount of organic acid present is equimolar to the total amount of nicotine present in the precursor and aerosol.

[00041] For aerosol delivery devices that are characterized as electronic cigarettes, the aerosol precursor most preferably includes tobacco or tobacco-derived components (referred to herein as “nicotine sources”). On the one hand, the tobacco may be provided in the form of pieces or pieces of tobacco, such as finely ground, shredded or powdered tobacco flakes. Alternatively, the tobacco may be provided in the form of an extract, such as a spray-dried extract, which includes many of the water-soluble components of tobacco. Alternatively, tobacco extracts may take the form of relatively high nicotine content extracts that also contain trace amounts of other extracted tobacco-derived components. On the other hand, tobacco-derived components may be provided in a relatively pure form, such as certain flavoring agents that are tobacco-derived. On the one hand, a component that is derived from tobacco and that can be used in a highly purified or substantially pure form is nicotine (eg, pharmaceutical grade nicotine).

[00042] In embodiments of the aerosol precursor material that contains a tobacco extract, including pharmaceutical grade nicotine derived from tobacco, it is preferred that the tobacco extract be characterized as being substantially free of compounds known collectively as Hoffman analytes, including, for example, Tobacco-specific nitrosamines (TSNAs), including N'-nitrosonornicotine (NNN), (4-methylnitrosamino)-1-(3-pyridyl)-1-butanone (NNK), N'-nitrosoanatabine (NAT), and N'-nitrosoanabasine (NAB); polyaromatic hydrocarbons (PAHs), including benzo[a]anthracene, benzo[a]pyrene, benzo[b]fluoranthene, benzo[k]fluoranthene, chrysene, dibenz[a,h]anthracene and indeno[1,2,3-cd ]pyrene and the like. In some embodiments, the aerosol precursor material may be characterized as being completely free of any Hoffman analytes, including TSNA and PAHs. Embodiments of the aerosol precursor material may have TSNA levels (or other Hoffman analyte levels) in the range of less than about 5 ppm, less than about 3 ppm, less than about 1 ppm, or less than about 0.1 ppm, or even less than any detectable limit. Certain extraction or treatment processes may be used to reduce the concentration of the Hoffman analyte. For example, the tobacco extract can be contacted with an imprinted polymer or an unimprinted polymer, such as described, for example, in US Pat. No. 9,192,193 to Byrd et al.; and in US Patent Publications No. 2007/0186940 by Bhattacharyya et al.; No. 2011/0041859 by Rees et al. and No. 2011/0159160 by Jonsson et al., all of which are incorporated herein by reference. In addition, tobacco extract can be treated with amine-functional ion exchange materials that can remove certain aldehydes and other compounds. See, for example, US Pat. No. 4,033,361 to Horsewell et al. and US Pat. No. 6,779,529 to Figlar et al., which are incorporated herein by reference in their entirety.

[00043] The aerosol precursor composition may undergo different conformations depending on the different amounts of materials used therein. For example, a suitable aerosol precursor composition may contain up to about 98% by weight, up to about 95% by weight, or up to about 90% by weight polyol. The total amount may be divided in any combination between two or more different polyols. For example, one polyol may contain from about 50% by weight to about 90% by weight, from about 60% by weight to about 90% by weight, or about 75% by weight aerosol precursor, and the second polyol may contain from about 2% by weight by weight to about 45% by weight, from about 2% by weight to about 25% by weight, or from about 2% by weight to about 10% by weight of the aerosol precursor. A suitable aerosol precursor may also contain up to about 30% by weight, up to about 25% by weight, up to about 20% by weight, or up to about 15% by weight water, in particular from about 2% by weight to about 30% by weight , from about 2% by weight to about 25% by weight, from about 5% by weight to about 20% by weight, or from about 7% by weight to about 15% by weight water. Flavorings and the like (which may include medications such as nicotine) may contain, for example, up to about 10% by weight, up to about 8% by weight, or up to about 5% by weight of aerosol precursor. Typically, although not limiting, flavor compounds other than nicotine may be present at levels ppm or μg/g or from about 0.004% to about 0.1%, some flavor compounds other than nicotine, such as menthol, may be present in higher amounts, for example, up to about 4% by weight (for example, from about 1.5% by weight to about 3% by weight) based on the aerosol precursor. Additionally, when using menthol, it may be preferable to minimize the amount of water in some embodiments so as not to result in precipitation of the menthol. In some embodiments, flavoring agents are included in the aerosol precursor solution in the form of an aerosol former solution (e.g., water, propylene glycol solution, and/or glycerol), and in such embodiments, the aerosol former solution containing the flavoring may be used in an amount of from about 5% by weight. weight up to about 10% by weight based on the total weight of the aerosol precursor, and one or more flavoring agents may be included therein at varying concentrations.

[00044] As a non-limiting example, the aerosol precursor in accordance with the invention may contain glycerin, propylene glycol, water, nicotine and one or more flavoring agents. In particular, glycerin may be present in an amount of from about 70% to about 90% by weight, from about 70% to about 85% by weight, from about 70% to about 80%, or from about 75% to about 85% by weight propylene glycol may be present in an amount from about 1% to about 10% by weight, from about 1% to about 8% by weight, or from about 2% to about 6% by weight, water may be present in an amount from about 1 to about 30% by weight by weight, for example from about 1 to about 25% by weight, from about 1 to about 10% by weight, from about 1 to about 5% by weight, from about 10 to about 25% by weight, from about 10 to about 20% by weight, from about 12 to about 20% by weight, from about 12 to about 16% by weight, nicotine may be present in an amount from about 0.1 to about 7% by weight, from about 0.1 to about 5% by weight by weight, from about 0.5 to about 4% by weight, or from about 1 to about 3% by weight, and flavorings may be present in an amount of up to about 5% by weight, up to about 3% by weight, or up to about 1% by weight , with all quantities calculated based on the total mass of the aerosol precursor. One specific non-limiting example of an aerosol precursor contains from about 75% by weight to about 80% by weight glycerol, from about 13% by weight to about 15% by weight water, from about 4% by weight to about 6% by weight propylene glycol, from about 2% by weight to about 3% by weight nicotine or from about 0.1% by weight to about 0.5% by weight flavorings. Nicotine, for example, may be present in the form of tobacco extract.

[00045] Another non-limiting example includes a greater amount of propylene glycol, such as from about 15% to about 40% by weight, such as from about 15% to about 30%, or from about 25% to about 35% by weight with glycerol present in less than the above non-limiting example, such as from about 40% to about 70% by weight, or from about 50% to about 70% by weight, water may be present in an amount from about 5 to about 20% by weight, from about 10 to about 18% by weight, or from about 12 to about 16% by weight, nicotine may be present in an amount from about 0.1 to about 7% by weight, from about 0.1 to about 5% by weight, from about 0.5 to about 4% by weight, or from about 1 to about 3% by weight, and flavorings may be present in amounts of up to about 5% by weight, up to about 3% by weight, or up to about 1% by weight, all amounts based on the total mass of the aerosol precursor.

[00046] Representative types of aerosol precursor components and compositions are also known and characterized in US Patent No. 7,726,320 to Robinson and US Patent Application Publication No. 2013/0008457 to Zheng et al.; No. 2013/0213417 by Chong and No. 2014/0060554 by Collett et al.; No. 2015/0020823 by Lipowicz et al.; and No. 2015/0020830 by Koller, and WO 2014/182736 by Bowen et al., the disclosures of which are incorporated herein by reference. Additional types of aerosol precursor compositions are listed in US Pat. No. 4,793,365 to Sensabaugh, Jr. et al., in US Patent No. 5,101,839 by Jakob et al., in PCT WO 98/57556 by Biggs et al., and in the monograph Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco (Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco). biological studies of new prototype cigarettes that heat tobacco instead of burning it) from the R. J. Reynolds Tobacco Company (1988), the disclosures of which are incorporated herein by reference. Examples of aerosol precursor compositions also include materials of the types that are included in devices available from Atlanta Imports Inc., Acworth, Georgia, USA, as an electronic cigar under the brand name E-CIG, which can be used using appropriate C1a smoking cartridges , C2a, C3a, C4a, C1b, C2b, C3b and C4b; as well as Ruyan Electronic Atomizing Tube and Ruyan Electronic Atomizing Cigarette from Ruyan SBT Technology and Development Co., Ltd., Beijing, China.

[00047] Other aerosol precursors that may be used include the aerosol precursors that are included in RJ Reynolds Vapor Company's ^VUSE® product, Lorillard Technologies' BLU™ product, Mistic Ecigs' MISTIC MENTHOL product, and CN Creative's VYPE product Ltd. Also preferred are so-called "smoke juices" for electronic cigarettes, which are available from Johnson Creek Enterprises LLC. Effervescent material embodiments may be used with the aerosol precursor as described, by way of example, in US Patent Application Publication No. 2012/0055494 to Hunt et al., which is incorporated herein by reference. In addition, the use of effervescent materials is described, for example, in US patents No. 4,639,368 to Niazi et al., No. 5,178,878 to Wehling et al., No. 5,223,264 to Wehling et al., No. 6,974,590 to Pather et al., no. 7,381,667 by Bergquist et al., and US Patent Application Publications No. 2006/0191548 by Strickland et al., No. 2009/0025741 by Crawford et al., No. 2010/018539 by Brinkley et al., no. 2010/0170522 by Sun et al. and PCT Application No. WO 97/06786 by Johnson et al., all of which are incorporated herein by reference.

[00048] According to the disclosed method, certain components of the aerosol precursor are combined in a specific order. An exemplary flow diagram showing the specific steps involved in producing an aerosol precursor is shown in FIG. 1. In particular, to prepare an aerosol precursor containing nicotine, nicotine is advantageously first combined with one or more organic acids. The combination of nicotine with one or more organic acids can be carried out in various solvents, but preferably the solvent includes water. The solvent may contain additional solvents in addition to water, which are preferably miscible with water and do not cause negative interaction with nicotine and/or organic acids. The order in which the nicotine, organic acid(s) and water are combined is not limited. For example, in some embodiments, nicotine and one or more organic acids are independently provided as aqueous solutions/dispersions, and the aqueous solutions/dispersions are combined. For example, in some embodiments, nicotine and one or more organic acids are combined and water is added thereto. In other embodiments, water is provided and nicotine and organic acid(s) (in pure/solid form or in aqueous solution/dispersion) are added thereto. In additional embodiments, pure nicotine is added to an aqueous solution/dispersion of one or more organic acids, and in other additional embodiments, one or more organic acids are added to an aqueous solution of nicotine. In some embodiments, nicotine is provided as a solution in glycerol. For example, such a nicotine solution may be combined with an aqueous solution or dispersion of organic acids.

[00049] The amount of solvent used for this mixing step may vary; however, in certain embodiments, it is advantageous to determine the maximum amount of a given solvent required in the final aerosol precursor and use an amount for that mixing step that is equal to or less than that maximum amount. For example, when the desired final aerosol precursor contains 5% by weight water or less, the amount of water used in the mixing step is preferably no more than that necessary to provide 5% by weight in the final aerosol precursor. If necessary, the amount of water in this mixture can be changed at will by adding more water to it or evaporating some of the water.

[00050] Without intending to be limited by theory, it is believed that in some embodiments the precursor combination of nicotine and organic acid(s) may help stabilize the nicotine and/or organic acid(s). In some embodiments, the initial combination of nicotine and organic acid(s) may result in the formation of nicotine salts (or other nicotine species, such as cocrystals) containing nicotine and organic acid(s). Nicotine salts with various co-formers are described, for example, in US Pat. No. 7,738,622 to Dull et al. and No. 9,215,895 to Bowen et al.; and US Patent Application Publications No. 2016/0185750 to Dull et al. and No. 20150020824 to Bowen et al., which are incorporated herein by reference in their entirety.

[00051] This step of combining nicotine with one or more organic acids typically results in the formation of an aqueous solution. By "aqueous solution" is meant a liquid in which at least a portion of the solvent contains water. Nicotine and organic acid(s) are generally completely dissolved, although the disclosure is not limited thereto, and mixtures of nicotine and organic acid(s) in which at least a portion of the nicotine and/or organic acid(s) are not completely dissolved may be used. , for example, in which some amount of solid matter is dispersed in a liquid phase.

[00052] In some embodiments, this combining step is conducted at substantially room temperature, i.e. The nicotine, organic acid(s) and solvent are not exposed to elevated temperature during the production of the aerosol precursor. In some embodiments, the disclosed method includes heating the nicotine, organic acid(s), and/or solvent(s) before or after combining. For example, in some embodiments, the mixture of nicotine and organic acid(s) in the solvent may be heated to facilitate dissolution of the nicotine and/or organic acid(s) in the solvent. Likewise, in some embodiments, the disclosed method further includes shaking the mixture at this stage of the preparation process. In some embodiments, shaking may promote complete mixing and dissolution of the nicotine and/or organic acid(s) in the solvent.

[00053] The specific methods and apparatus used to mix these components may vary. In some embodiments, this combining step may be carried out in a conventional laboratory glassware, such as a beaker or round bottom flask, with appropriate stirring (eg, a paddle stirrer or magnetic stirrer). Such laboratory equipment can be used to combine/mix the components of an aqueous solution, as well as additional ingredients, to produce an aerosol precursor. In some embodiments, a calorimeter (eg, a Mettler Toledo RC1 calorimeter) can be used to monitor the amount of reaction heat generated. Advantageously, large drums, steel vessels or glass-lined jacketed reactors, such as those available from Pfaudler, can be used to combine the mixing of the aqueous solution components as well as additional ingredients to produce the aerosol precursor.

[00054] Once the aqueous solution is prepared as described above herein, various other components may be included to produce the final aerosol precursor. For example, the disclosed method typically further includes adding one or more "aerosol former" components, as defined hereinabove, to the aqueous solution. The disclosed method may further include adding one or more additional components needed in the final aerosol precursor, such as flavoring agents. Such additional components may be added independently or as mixtures of one or more such components. Additional components may be included by any means known in the art and in varying amounts. Typically, the aqueous solution, when heated during the initial mixing step, is cooled to room temperature before one or more additional components are added thereto. Further mixing may occur between each addition when multiple components are added separately and/or after all components have been combined. Again, heating and/or stirring can be used at any stage of the process, for example to aid dissolution/mixing. In one embodiment, the entire method is carried out without the application of heat, i.e. The method is performed at room temperature. Preferably, at least the majority of the process is carried out in the absence of heat, i.e. most of the process is carried out at room temperature. In one embodiment, to create an aqueous solution, nicotine and one or more organic acids are combined in water, and then one or more flavoring agents are added thereto, and then one or more aerosol formers (e.g., polyols/polyhydric alcohols) are added to form a precursor. aerosol.

[00055] Preferably, by first combining nicotine and organic acid(s) in the absence of such "aerosol former" components (other than water, which is used in the first mixing step), unwanted reactions between the organic acid(s) and the aerosol former components may be kept to a minimum. In particular, combining nicotine and organic acid(s) in the absence of polyols/polyols can minimize the loss of organic acid(s) by forming esters with polyols/polyols. Thus, the mixing method described herein can provide an aerosol precursor formulation with an organic acid(s) content that approximately corresponds to the expected amount of organic acid(s) in the aerosol precursor.

[00056] For example, the amount "A" of organic acid is calculated to ideally provide the desired weight percentage "x" of organic acid A in the aerosol precursor, and thus the amount "A" of organic acid is used in the disclosed method. Preferably, based on the disclosed method, the actual weight percentage of organic acid A in the aerosol precursor does not differ significantly from "x". For example, in some embodiments, the concentration of one or more organic acids in the aerosol precursor is no more than about 25% less than the target, no more than about 20% less than the target, no more than about 10% less than the target, or no more than approximately 5% less than target. When more than one different organic acid is used in the disclosed method, each organic acid may independently meet these limitations and/or the organic acids in combination may meet these limitations. For example, in some embodiments, the concentration of one or more organic acids in the aerosol precursor is independently no more than about 25% less than the target, no more than about 20% less than the target, no more than about 10% less than the target , or no more than about 5% less than the target, and/or the total concentration of organic acids in the aerosol precursor is no more than about 25% less than the target, no more than about 20% less than the target, no more than about 10% less than the target or no more than 5% less than the target.

[00057] It should be noted that while the disclosure relates primarily to a method in which nicotine is independently combined with organic acid(s) in the absence of aerosol former components (other than water), it is not limited thereto. Certain advantages of the invention can be seen in an alternative embodiment, for example, when the organic acids and aerosol former components are combined and nicotine is added thereto. Without intending to be limited by theory, it is believed that in some such systems the formation of a nicotine salt (i.e., the reaction between nicotine and one or more organic acids) may be more rapid than the undesired reaction between the organic acid(s) and the excipient(s). aerosol. Therefore, such methods should also be included within the scope of the disclosed invention.

[00058] The method of the invention, which results in retention of more of the added organic acid(s) in the aerosol precursor, provides certain advantages. For example, it will be understood that organic acids in the aerosol precursor may be useful in causing protonation of at least a portion of the nicotine present in the aerosol precursor. Such protonation desirably results in the formation of an aerosol of the precursor that provides a low to moderate pungency in the user's throat. It is generally understood that if too little acid is included in the aerosol precursor, more nicotine will remain unprotonated and the user will experience an increased throat burn in the gas phase of the aerosol. See, for example, US Patent Application Publication No. 20150020823 to Lipowicz et al., which is incorporated herein by reference. Thus, methods of the invention that can provide an amount of organic acid(s) in the aerosol precursor that is close to the target amount can result in desired sensory/taste characteristics (eg, reduced pungency).

[00059] In some embodiments, the pH of the aerosol precursor can be maintained within a desired range. Again, by limiting the number of side reactions, the target pH of the aerosol precursor can be more accurately achieved. In some embodiments, the method disclosed herein further provides an aerosol precursor with reduced byproduct content. Again, the present method is designed to specifically avoid certain interactions between components of the aerosol precursor and, accordingly, by minimizing such interactions, fewer byproducts can be formed. In general, the disclosed method can provide greater control over the composition (eg, amount of organic acid(s), amount of undesired byproducts, etc.) and characteristics (eg, pH, stability) of the aerosol precursor composition thus obtained.

[00060] In some embodiments, there may be additional benefits associated with performing the production of the aerosol precursor at substantially room temperature (with the majority of the process being conducted without the addition of heat). By not subjecting the components of the aerosol precursor to heat, the resulting product may, in some embodiments, be more stable and, in some embodiments, may exhibit amounts of various components that are close to the target amounts of such components.

[00061] The disclosed method may further include incorporating an aerosol precursor into the aerosol delivery system, as is generally known in the art. Aerosol delivery systems generally use electrical energy to heat a material (preferably without burning the material to any significant extent) to produce an inhalable agent; and the components of such systems are in the form of articles, most preferably compact enough to be considered portable devices. In other words, the use of the components of the preferred aerosol delivery systems does not produce smoke in the sense that the aerosol arises primarily from by-products of combustion or pyrolysis of tobacco, but rather, the use of the preferred systems results in the formation of vapors generated by the evaporation or evaporation process of certain components included in them. In some embodiments, the components of aerosol delivery systems may be characterized as electronic cigarettes, and said electronic cigarettes most preferably include tobacco and/or tobacco-derived components and thereby deliver tobacco-derived components in an aerosol form. Aerosol delivery systems, which may include aerosol precursors formulated as disclosed herein, may also be characterized as vaporization or drug delivery products. Thus, such articles or devices may be adapted to deliver one or more substances (eg, flavoring agents and/or pharmaceutical active ingredients) in an inhalable form or state. For example, the inhaled substances may be essentially in the form of a vapor (eg, a substance that is in the gaseous phase at a temperature below its critical point). Alternatively, the inhaled substances may be in aerosol form (ie, a suspension of fine solid particles or liquid droplets in a gas). For the sake of simplicity, as used herein, the term “aerosol” is intended to refer to vapors, gases and aerosols of a form or type suitable for human inhalation, whether or not visible and whether or not in a form that may be considered "smoke-like".

[00062] Aerosol delivery systems generally comprise a number of components located within an outer housing or shell, which may be referred to as a casing. The overall design of the outer housing or shell may vary, and the configuration and format of the outer housing, which may define the overall size and shape of the aerosol delivery device, may also vary. Typically, an elongated body resembling the shape of a cigarette or cigar may be formed from one single housing, or the elongated housing may be formed from two or more separable housings. For example, an aerosol delivery device may comprise an oblong casing or body that may be substantially tubular in shape and thus resemble the shape of a conventional cigarette or cigar. In one example, all components of the aerosol delivery device are located in a single housing. Alternatively, the aerosol delivery device may comprise two or more housings that are connected and removable. For example, an aerosol delivery device may have at one end a control housing containing a housing containing one or more reusable components (e.g., a battery, such as a rechargeable battery and/or capacitor, and various electronic equipment for controlling the operation of the product), and at the other end at the end, a removably attached outer housing or shell containing a disposable portion (for example, a disposable cartridge containing a flavor). See also the device types set forth in US Patent Application No. 15/708,729 by Sur et al., filed September 19, 2017 and US Patent Application No. 15/417,376 by Sur et al., filed January 27, 2017 g., which are incorporated herein by reference in their entirety.

[00063] Aerosol delivery systems according to the disclosure of the present invention most preferably comprise some combination of a power source (e.g., an electrical power supply), at least one control component (e.g., means for actuating, controlling, regulating, and stopping power to generate heat, for example, by controlling electrical current from a power source to other components of the product -- for example, an analog electronic control component), a heater, or a heat-producing element (for example, an electrical resistive heating element or other component, either alone or in combination with one or more additional elements may be generically referred to as an "atomizer"), aerosol precursor compositions (e.g., typically a liquid capable of forming an aerosol when sufficient heat is applied; such ingredients are typically referred to as "smoke juice," "e-liquid," and "e-juice"), and mouthpiece area or tip to permit puffing through an aerosol delivery device for inhalation of the aerosol (eg, a defined air flow path through the article so that the generated aerosol can be discharged therefrom after puffing).

[00064] The selection and arrangement of various components of aerosol delivery systems can be understood, for example, by considering commercially available electronic aerosol delivery devices, such as those representative products referenced in the Background section of the disclosure of the present invention. In various examples, the aerosol delivery device may comprise a reservoir configured to hold the aerosol precursor composition. In particular, the reservoir may be formed from a porous material (eg, fibrous material) and thus may be referred to as a porous support (eg, fibrous support). The reservoir may also be contained within or otherwise surrounded by ferritic material to facilitate induction heating.

[00065] The fibrous support used as a reservoir in the aerosol delivery device may be a woven or non-woven material formed from a plurality of fibers or filaments, and may be formed from natural fibers and/or synthetic fibers. For example, the fibrous substrate may comprise glass fiber material. In specific examples, cellulose acetate material may be used. In other embodiments, carbon material may be used. The reservoir may be substantially in the form of a container and may contain fibrous material contained therein.

[00066] In FIG. 2 is a side view of an aerosol delivery device 100 including a control housing 102 and a cartridge 104 in accordance with various exemplary embodiments of the present invention. In particular, in FIG. 1 shows the control housing and the cartridge, which are connected to each other. The control housing and cartridge can be aligned to allow operation and disconnection. Various mechanisms may connect the cartridge and the control body, for example, in the form of a threaded coupling, a press-fit coupling, an interference fit, a magnetic coupling, and the like. In some exemplary embodiments, the aerosol delivery device may be substantially rod-shaped, substantially tubular in shape, or substantially cylindrical in shape when the cartridge and control housing are in an assembled configuration. The aerosol delivery device may also be substantially rectangular or diamond-shaped in cross section, which may make it more compatible with a substantially planar or thin film power supply, such as a power supply comprising a coin cell battery. The cartridge and control body may comprise respective separate housings or outer housings, which may be formed from any number of different materials. The casing may be formed from any suitable structurally sound material. In some examples, the housing may be formed from a metal or alloy, such as stainless steel, aluminum, or the like. Other suitable materials include various types of plastics (eg, polycarbonate), metal-coated plastics, ceramics, and the like.

[00067] In some example implementations, the control housing 102 and/or the cartridge 104 of the aerosol delivery device 100 may be disposable or reusable. For example, the control housing may have a replaceable battery or a rechargeable supercapacitor, and thus be combined with any type of recharging technology, including connection to a regular wall electrical outlet, connection to a car charger (e.g., cigarette lighter socket), connection to a computer, e.g. , via a Universal Serial Bus (USB) cable or connector, wireless connection to a radio frequency (RF) charger, connection to a photovoltaic cell (sometimes listed as a solar photovoltaic cell) or to a solar photovoltaic cell panel. Some examples of suitable recharge technologies are described below. Also, in some embodiments, the cartridge may be a disposable cartridge, as described in US Patent No. 8,910,639 to Chang et al., which is incorporated herein by reference.

[00068] In FIG. 3 shows in more detail an aerosol delivery device 100 in accordance with some example implementations. As seen in the partial sectional view, the aerosol delivery device may include a control housing 102 and a cartridge 104, each of which contains a plurality of associated components. The components shown in FIG. 3 are representative of the components that may be present in the control housing and cartridge and are not intended to limit the scope of the components covered by the disclosure of the present invention. As shown, for example, the control housing may be formed by a control housing shell 206, which may include various electronic components, such as a control component 208 (e.g., an electronic analog component), a sensor 210, a power supply 212, and one or more light-emitting diodes 214 (e.g. , organic light-emitting diodes (OLEDs)), and such components can be aligned in various ways. The flow sensor may include a number of suitable sensors, such as an accelerometer, gyroscope, optical sensor, proximity sensor, or the like.

[00069] Power supply 212 may be or include a suitable power source, such as a lithium-ion battery, solid-state battery, or supercapacitor, as disclosed in US patent application No. 14/918926 by Sur et al., which is included in this document by reference. Examples of suitable solid-state batteries are the EnMilm™ rechargeable solid-state lithium thin-film batteries from STMicroelectronics. Examples of suitable supercapacitors include an electrical double layer capacitor (EDLC), a hybrid capacitor such as a lithium ion capacitor (LIC), or the like.

[00070] In some example implementations, power supply 212 may be a rechargeable power supply configured to supply current to control component 208 (eg, an analog electronic component). In these examples, the power supply may be connected to the charging circuit through a resistive temperature sensor (RTD). The RTD may be configured to alert the charging circuit when the temperature of the power supply exceeds a threshold, and the charging circuit may disable charging of the power supply in response thereto. In these examples, safe charging of the power supply may be provided independently of the digital processor (eg, microprocessor) and/or digital processing logic.

[00071] LED 214 may be one example of a suitable visual indicator that aerosol delivery device 100 may be equipped with. In some examples, LEDs may include organic light-emitting diodes, quantum dot light-emitting diodes. Other indicators, such as audible indicators (e.g., speakers), tactile indicators (e.g., vibration motors), or the like, may be included in addition to or as an alternative to visual indicators, such as light-emitting diodes, including organic light-emitting diodes or quantum dot light-emitting diodes .

[00072] The cartridge 104 may be formed by a cartridge shell 216 enclosing a reservoir 218 that is in fluid communication with a liquid transfer element 220 configured to absorb or otherwise transfer an aerosol precursor composition stored in the reservoir shell to a heater 222 (sometimes called a heating element). In various configurations, this structure may be called a container; and accordingly, the terms “container,” “cartridge,” and the like may be used interchangeably to refer to a shell or other casing enclosing a reservoir for the aerosol precursor composition and containing a heater. In some examples, a valve may be located between the reservoir and the heater and configured to control the amount of the aerosol precursor composition passed through or delivered from the reservoir to the heater.

[00073] Various examples of materials configured to generate heat when electrical current is applied to them may be used to form the heater 222. The heater in these examples may be a resistive heating element such as a wire coil, a microheater, and the like. Examples of materials from which helix wire can be made include fechral (FeCrAl), nichrome, molybdenum disilicide ( _MoSi2 ), molybdenum silicide (MoSi), aluminum alloyed molybdenum disilicide (Mo(Si,Al) ₂ ), titanium (Ti) , graphite and graphite-based materials (such as carbon-based foams and filaments), and ceramics (such as PTC and NTC ceramics). Example implementations of heaters or heating elements used in aerosol delivery devices in accordance with the disclosure of the present invention are further described below, and may be included in devices such as those shown in FIG. 3 as described herein.

[00074] An opening 224 may be located in the cartridge shell 216 (e.g., at the tip of a mouthpiece) to allow the generated aerosol to exit the cartridge 104. In addition to the heater 22, the cartridge 104 may also contain one or more other electronic components 226. These electronic components may contain an integrated circuit, memory component, sensor or the like. The electronic components may be configured to communicate with the control component 208 and/or an external device through wired or wireless means. Electronic components may be located anywhere in the cartridge or base 228 thereof.

[00075] Although control component 208 and sensor 210 are shown separately, it should be understood that the control component and sensor may be combined on an electronic circuit board. Moreover, the electronic circuit board may be positioned horizontally relative to the illustration of FIG. 3, in which the electronic circuit board can be longitudinally parallel to the central axis of the control housing. In some examples, the sensor may include its own circuit board or other base element to which it can be attached. In some examples, a flexible circuit board may be used. The flexible circuit board can be made in a variety of shapes, including substantially tubular shapes. In some examples, the flexible circuit board may be combined with a heater substrate, layered thereon, or may form part or all of the heater substrate, as further described below.

[00076] The control housing 102 and the cartridge 104 may include components configured to facilitate fluid interaction with each other. As shown in FIG. 3, the control body may include a connector 230 having a cavity 232 therein. The cartridge base 228 may be configured to engage the connector and may include a projection 234 configured to be recessed into the cavity. Such interaction may facilitate a stable connection between the control housing and the cartridge and establish an electrical connection between the power supply 212 and the control component 208 in the control housing and the heater 222 in the cartridge. Also, the control housing shell 206 may include an air intake 236, which may be a recess in the shell in which it is connected to the connector, allowing air from the environment around the connector to pass into the shell, where it then passes through the connector cavity 232 into the cartridge through the projection 234 .

[00077] In use, heater 222 is activated to vaporize components of the aerosol precursor composition. Drawing through the mouthpiece of the aerosol delivery device causes ambient air to enter the air intake 236 and pass through the cavity 232 in the connector 230 and the central opening of the projection 234 of the base 228. At the cartridge 104, the drawn air combines with the generated vapor to form an aerosol. The aerosol is removed by sucking, drawing, or otherwise puffing from the heater and exits an opening 224 in the mouthpiece of the aerosol delivery device.

[00078] A connector and base suitable for use in accordance with the disclosure of the present invention are described in US Patent Application Publication No. 2014/0261495 to Novak et al., which is incorporated herein by reference in its entirety. For example, connector 230, as shown in FIG. 3 may define an outer periphery 238 configured to mate with an inner periphery 240 of the base 228. In one example, the inner periphery of the base may have a radius substantially equal to or slightly greater than the radius of the outer periphery of the connector. The connector may also define one or more projections 242 on the outer periphery configured to engage one or more recesses 244 formed on the inner periphery of the base. However, various other exemplary designs, shapes, and components may be used to connect the base to the connector. In some examples, the connection between the cartridge base 104 and the control housing connector 102 may be substantially permanent, while in other examples, said connection between them may be removable so that, for example, the control housing can be reused with one or more additional cartridges, which can be disposable and/or reusable.

[00079] In some example implementations, the aerosol delivery device 100 may be substantially rod-shaped or substantially tubular in shape or substantially cylindrical in shape. In other examples, additional shapes and sizes are covered, such as rectangular or triangular cross-sections, polyhedral shapes, and the like.

[00080] Reservoir 218 shown in FIG. 3 may be a container or fibrous reservoir as described herein. For example, in this example, the reservoir may comprise one or more layers of nonwoven fiber and may be substantially formed in the shape of a tube surrounding the interior of the cartridge shell 216. The aerosol precursor composition may be retained in a reservoir. Liquid components, for example, can be retained by sorption in a reservoir. The reservoir may be in fluid communication with the fluid transfer element 220. In this example, the liquid transfer element may transfer the aerosol precursor composition stored in the reservoir by capillary action to the heater 222, which is a coil of metal wire. Typically, the heater is located in a heating device with a liquid transfer element. Example implementations of reservoirs and transfer elements used in aerosol delivery devices in accordance with the disclosure of the present invention are further described below, and such reservoirs and/or transfer elements may be included in devices such as those shown in FIG. 3 as described herein. In particular, specific combinations of heating elements and transfer elements may be included in devices such as those shown in FIG. 3 as described herein.

[00081] The various components of the aerosol delivery device may be selected from components described in the prior art and commercially available. Examples of batteries that can be used in accordance with the invention are described in US Patent Application Publication No. 2010/0028766 by Peckerar et al., which is incorporated herein by reference.

[00082] The aerosol delivery device 100 may also include a sensor 210 or other sensor or sensing element for controlling the supply of electrical power to the heater 222 when aerosol production is required. Thus, for example, a method or method is provided for turning off electrical power to the heater when the aerosol delivery device is in use and turning on electrical power to drive or start generating heat by the heater during a puff. Additional characteristic types of sensing and detection mechanisms, their structure and configuration, their components and general methods of their operation are described in US Patent No. 5,261,424 to Sprinkel, Jr., US Patent No. 5,372,148 to McCafferty et al., and the publication of the application for PCT Patent No. WO 2010/003480 by Flick, all of which are incorporated herein by reference in their entirety.

[00083] The aerosol delivery device 100 most preferably includes a control component 208 or other control mechanism for controlling the amount of electrical power supplied to the heater 222. Representative types of electronic components, their structure and configuration, their features and general methods of operation are described in US Patent No. 4,735,217 by Gerth et al., US Patent No. 4,947,874 by Brooks et al., US Patent No. 5,372,148 by McCafferty et al., US Patent No. 6,040,560 by Fleischhauer et al., US Patent No. 7,040,314 by Nguyen et al., US Patent No. 8,205,622 to Pan, US Patent Application Publication No. 2009/0230117 to Fernando et al., US Patent Application Publication No. 2014/0060554 to Collet et al., published US Patent Application No. 2014/0270727 to Ampolini et al., and US Patent Application Publication No. 2015/0257445 to Henry et al., all of which are incorporated herein by reference in their entirety.

[00084] Representative types of substrates, reservoirs or other components for supporting an aerosol precursor are described in US Patent No. 8,528,569 to Newton, US Patent Application Publications No. 2014/0261487 to Chapman et al., US Pat. No. 2015/0059780 to Davis and al., and No. 2015/0216232 by Bless et al., all of which are incorporated herein by reference in their entirety. Also, various absorbent materials, as well as the design and operation of these absorbent materials in certain types of electronic cigarettes, are described in US Patent Application Publication No. 2014/0209105 to Sears et al., which is incorporated herein by reference in its entirety.

[00085] Additional characteristic types of components that provide visual signals or indicators may be used in the aerosol delivery device 100, such as visual indicators and related components, auditory indicators, tactile indicators, and the like. Examples of suitable light-emitting diode components, as well as their design and use, are described in US Patent No. 5,154,192 to Sprinkel et al., US Patent No. 8,499,766 to Newton, US Patent No. 8,539,959 to Scatterday, and US Patent No. 9,451,791 to by Sears et al., all of which are incorporated herein by reference in their entirety.

[00086] Other features, controls or components that may be contained in aerosol delivery devices according to the disclosure of the present invention are described in US Patent No. 5,967,148 to Harris et al., in US Patent No. 5,934,289 to Watkins et al., in Patent U.S. No. 5,954,979 to Counts et al., U.S. Patent No. 6,040,560 to Fleischhauer et al., U.S. Patent No. 8,365,742 to Hon, U.S. Patent No. 8,402,976 to Fernando et al., U.S. Patent Application Publication No. 2005/0016550 by Katase, US Patent Application Publication No. 2010/0163063 by Fernando et al., US Patent Application Publication No. 2013/0192623 by Tucker et al., US Patent Application Publication No. 2013/ 0298905 by Leven et al., US Patent Application Publication No. 2013/0180553 by Kim et al., US Patent Application Publication No. 2014/0000638 by Sebastian et al., US Patent Application Publication No. 2014 /0261495 by Novak et al., and US Patent Application Publication No. 9,220,3022014/0261408 by DePiano et al., all of which are incorporated herein by reference in their entirety.

[00087] Control component 208 contains a plurality of electronic components and, in some examples, may be formed on a printed circuit board (PCB) that supports and electrically connects the electronic components. The electronic components may include an analog electronic component configured to operate independently of a digital processor (eg, a microprocessor) and/or digital processing logic. In some examples, the control component may be coupled to a communications interface to provide wireless connectivity to one or more networks, computing devices, or other devices on a suitable basis. Examples of suitable communication interfaces are disclosed in US Patent Application Publication No. 2016/0261020 by Marion et al., the contents of which are incorporated herein by reference in their entirety. And examples of suitable methods by which an aerosol delivery device can be configured to communicate wirelessly are disclosed in US Patent Application Publication No. 2016/0007651 to Ampolini et al., and US Patent Application Publication No. 2016/0219933 to Henry , Jr. and others, each of which is incorporated herein by reference in its entirety.

EXAMPLE

[00088] Organic acids are added to the mixing vessel, and water is added. The mixture is stirred until dissolved to obtain an aqueous solution. Nicotine is slowly added to the aqueous solution, and the solution is subsequently cooled to room temperature (if necessary). Flavoring is added to the cooled aqueous solution. Subsequently, aerosol formers are added and the mixture is thoroughly mixed until a homogeneous mixture is obtained.

[00089] Various such mixtures were prepared and analyzed for acid content. The acid content was found to be substantially comparable to the target acid content. The mixtures were kept for 6 weeks at room temperature in opaque vials and acid levels were found to remain constant over this period of time. In addition, other comparable mixtures were aged in opaque bottles for 4 weeks at room temperature followed by accelerated testing conditions (40°C/75% RH in an environmental chamber). Again, acid levels were found to remain constant during this time period/accelerated condition study.

[00090] Many modifications and other embodiments of the present invention set forth herein will be apparent to one skilled in the art to which this invention relates using the disclosures set forth in the foregoing description and accompanying drawings. Thus, it is to be understood that the present invention is not limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Moreover, while the foregoing description and accompanying drawings disclose exemplary implementations in the context of certain exemplary combinations of elements and/or functions, it is to be understood that various combinations of elements and/or functions may be provided in alternative embodiments without departing from the scope of the appended claims. In this regard, for example, combinations of elements and/or functions other than those expressly described above are also intended, as may be indicated in certain claims of the appended claims. Although specific terms are used herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims (17)

1. A method for producing an aerosol precursor composition, comprising: obtaining an aqueous solution containing one or more organic acids and nicotine in water; combining said aqueous solution with one or more vaporizers to produce an aerosol precursor composition; and incorporating the aerosol precursor composition into the aerosol delivery device, wherein the aqueous solution contains at least one of the organic acids in a predetermined amount and the aerosol precursor composition contains at least one organic acid in a final amount that is about 75% or more of the predetermined amount. 2. The method of claim 1, wherein the final amount is about 80% or more of the target amount. 3. The method of claim 1, wherein the final amount is about 90% or more of the target amount. 4. The method of claim 1, wherein the aqueous solution contains one or more organic acids in a predetermined amount and the aerosol precursor composition contains one or more organic acids in a final amount that is close to the predetermined amount. 5. The method of claim 4, wherein the final amount is about 75% or more of the target amount. 6. The method of claim 4, wherein the final amount is about 80% or more of the target amount. 7. The method of claim 4, wherein the final amount is about 90% or more of the target amount. 8. Method according to any one of paragraphs. 1-7, according to which one or more organic acids are selected from the group consisting of levulinic acid, succinic acid, lactic acid, pyruvic acid, benzoic acid, fumaric acid and combinations thereof. 9. Method according to any one of paragraphs. 1-7, according to which one or more vapor formers are polyols. 10. Method according to any one of paragraphs. 1-7, according to which the preparation and combination steps are performed in the absence of added heat. 11. Method according to any one of paragraphs. 1-7, according to which, to obtain an aqueous solution, the preparation step includes a treatment selected from heating, shaking, stirring and combinations thereof. 12. Method according to any one of paragraphs. 1-7, further including adding additional components before or after the combining step. 13. The method according to claim 12, according to which the additional components are flavoring agents.

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