US20250212938A1 - A composition comprising an agglomerate comprising an aerosol-generating material and uses thereof - Google Patents

A composition comprising an agglomerate comprising an aerosol-generating material and uses thereof Download PDF

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US20250212938A1
US20250212938A1 US18/851,550 US202318851550A US2025212938A1 US 20250212938 A1 US20250212938 A1 US 20250212938A1 US 202318851550 A US202318851550 A US 202318851550A US 2025212938 A1 US2025212938 A1 US 2025212938A1
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aerosol
composition
generating material
dried
generating
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Matthew Hodgson
John Richardson
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Nicoventures Trading Ltd
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Nicoventures Trading Ltd
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Assigned to Nicoventures Trading Limited reassignment Nicoventures Trading Limited ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HODGSON, MATTHEW, RICHARDSON, JOHN, BRITISH AMERICAN TOBACCO (INVESTMENTS) LIMITED
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    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
    • A24B15/00—Chemical features or treatment of tobacco; Tobacco substitutes, e.g. in liquid form
    • A24B15/10—Chemical features of tobacco products or tobacco substitutes
    • A24B15/12—Chemical features of tobacco products or tobacco substitutes of reconstituted tobacco
    • A24B15/14—Chemical features of tobacco products or tobacco substitutes of reconstituted tobacco made of tobacco and a binding agent not derived from tobacco
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
    • A24B15/00—Chemical features or treatment of tobacco; Tobacco substitutes, e.g. in liquid form
    • A24B15/10—Chemical features of tobacco products or tobacco substitutes
    • A24B15/16—Chemical features of tobacco products or tobacco substitutes of tobacco substitutes
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
    • A24B15/00—Chemical features or treatment of tobacco; Tobacco substitutes, e.g. in liquid form
    • A24B15/18—Treatment of tobacco products or tobacco substitutes
    • A24B15/186—Treatment of tobacco products or tobacco substitutes by coating with a coating composition, encapsulation of tobacco particles
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
    • A24B15/00—Chemical features or treatment of tobacco; Tobacco substitutes, e.g. in liquid form
    • A24B15/18—Treatment of tobacco products or tobacco substitutes
    • A24B15/28—Treatment of tobacco products or tobacco substitutes by chemical substances
    • A24B15/30—Treatment of tobacco products or tobacco substitutes by chemical substances by organic substances
    • A24B15/302—Treatment of tobacco products or tobacco substitutes by chemical substances by organic substances by natural substances obtained from animals or plants
    • A24B15/303—Plant extracts other than tobacco
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES OF CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
    • A24D1/00—Cigars; Cigarettes
    • A24D1/20—Cigarettes specially adapted for simulated smoking devices

Definitions

  • composition comprising an agglomerate comprising a plurality of particles of an aerosol-generating material comprising a dried precursor material comprising an extract from a flavour- and/or active-containing plant material.
  • the agglomerate has a BET surface area of at least about 100 m 2 /g.
  • the agglomerate consists essentially of the dried aerosol-generating material and an optional binder.
  • the precursor material comprises from 0 to about 40% by weight of an excipient.
  • the dried aerosol-generating material comprises from about 99 to about 45% by weight dried extract from the flavour- or active-containing plant material.
  • the dried aerosol-generating material comprises from about 1 to about 34% by weight of an aerosol-former material.
  • the dried aerosol-generating material comprises from 0 to about 25% by weight of an excipient.
  • the plant material is selected from the group consisting of tobacco, eucalyptus, star anise, cocoa and hemp.
  • the extract from a flavour- or active-containing plant material is an aqueous extract.
  • the extract from a flavour- or active-containing plant material is an aqueous tobacco extract.
  • the dried aerosol-generating material comprising from about 40 to about 99% by weight tobacco solids.
  • the dried aerosol-generating material having a water content of no more than about 5% (calculated on a wet weight basis).
  • the composition comprises a sorbent material.
  • the dried aerosol-generating material may be hygroscopic and so measures may need to be taken to ensure that the aerosol-generating material does not absorb moisture during processing, incorporation into a final product and storage in that final product prior to use.
  • compositions comprising an agglomerate comprising a plurality of particles of an aerosol-generating material comprising a dried precursor material comprising an extract from a flavour- and/or active-containing plant material and, optionally an aerosol-former material.
  • the agglomerate is a low density agglomerate, with the agglomeration and binding of the particles of aerosol-generating material resulting in gaps between the particles making up the agglomerate. These gaps mean that the agglomerate is porous, with channels being formed throughout the agglomerate and, in some embodiments, rendering the agglomerate sufficiently porous so that air may be drawn through the agglomerate.
  • Such low density agglomerates will also have a relatively high surface area.
  • Agglomerates with a high porosity/high surface area/low density have the advantages of providing passages within the agglomerate through which the aerosol generated upon heating the aerosol generating material can escape and is therefore available to be delivered to the user.
  • the high porosity/high surface area/low density of the agglomerate may also assist the transfer of heat throughout the agglomerate, thus ensuring that all of the aerosol-generating material in the agglomerate is adequately heated to generate the desired aerosol.
  • the transfer of heat may also be faster than in higher density agglomerates.
  • compositions as described herein, comprising agglomerated particles of aerosol-generating material can allow the release of the aerosol to be controlled.
  • the density and porosity of one or more agglomerates may be selected to provide a composition that has the desired aerosol release characteristics.
  • the surface area of porous materials may be estimated by measuring the variation of the volume of nitrogen adsorbed by the material in relation to the partial pressure of nitrogen at a constant temperature. Analysis of the results by mathematical models originated by Brunauer, Emmett and Teller results in a value known as the BET surface area.
  • agglomerates of the present invention with high BET surface areas may be preferred over agglomerates with low BET surface areas. This is because agglomerates with high BET surface areas are likely to exhibit faster and possibly even greater aerosol generation than agglomerates with low BET surface areas.
  • agglomerates with different BET surface areas may be combined, to provide a staggered release of aerosol and to provide aerosol generation over an extended period of time, for example for a session of multiple puffs of aerosol.
  • At least some of the agglomerates used in the present invention have a BET surface area of at least about 100, at least about 150, at least about 200, at least about 250, at least about 300, at least about 350, at least about 400, at least about 450, at least about 500, at least about 550, at least about 600, at least about 650, at least about 700, at least about 750, at least about 800, at least about 900, or at least about 1000 m 2 /g.
  • a balance needs to be struck between the porosity of the agglomerates and their structural stability and integrity. Agglomerates with very high porosity may tend to be fragile and may readily break apart before use.
  • an agglomerate comprises a plurality of particles, all of which comprise the aerosol-generating material formed by drying the precursor material described herein.
  • an agglomerate may further include particles of other material.
  • the agglomerates may further comprise particles of a different aerosol-generating material, such as particles of tobacco material or particles of a gel or dried gel.
  • the particles of aerosol-generating material may be agglomerated with particles of other materials, to give the agglomerate desired properties such as density, porosity, absorption or adsorption.
  • the agglomerate may include particles of one or more structural materials, such as chalk.
  • this material may also absorb moisture and therefore reduce the amount of moisture absorbed by the dried extract.
  • the agglomerates comprise particles that comprise and/or hold flavour.
  • the tackiness of the particles may be increased by adding an aerosol-former material, such as glycerol.
  • an aerosol-former material such as glycerol.
  • the agglomerate does not comprise a binder to assist agglomeration of the particles in the agglomerate.
  • the coating will be thick enough to confer the desired moisture impermeability.
  • the thickness of the coating may, in some embodiments, further influence the temperature at which the coating becomes permeable and allow volatile components generated by heating the dried aerosol-generating material to be released from the composition.
  • the moisture impermeable coating has a thickness of from about 1 ⁇ m to about 100 ⁇ m.
  • the thickness of the moisture-impermeable coating applied to a particle or portion of aerosol-generating material may vary by as much as 50% or more. In some embodiments, this will result in a coating which does not decompose in a uniform manner. For example, areas where the coating is thinner may tend to decompose faster. This may help to provide a more gradual and sustained release of the aerosol generated by heating the particle or portion of aerosol-generating material.
  • extended and controlled release of the volatile components may be achieved by the composition comprising discrete agglomerates of the dried aerosol-generating material that are surrounded by coatings of different thickness.
  • the agglomerate comprising the aerosol-generating material has the desired particle size and shape before the moisture-impermeable coating is applied.
  • the coating is applied directly onto the surface of the aerosol-generating material.
  • the coating may be applied to the surface of the agglomerate, or to the surface of the particles making up the agglomerate (i.e. it is applied to these particles before they are agglomerated).
  • the coating is applied to the surface of the aerosol-generating material in the form of a powder.
  • the average particle size of the coating powder is from about 100 nm to about 50 ⁇ m.
  • the average particle size of the coating powder is at least about 100 nm, at least about 200 nm, at least about 300 nm, at least about 400 nm, at least about 500 nm, at least about 600 nm, at least about 700 nm, at least about 800 nm, at least about 900 nm, at least about 1 ⁇ m, at least about 2 ⁇ m, at least about 3 ⁇ m, at least about 4 ⁇ m, at least about 5 ⁇ m, at least about 10 ⁇ m, at least about 15 ⁇ m, at least about 20 ⁇ m, at least about 25 ⁇ m, at least about 30 ⁇ m, at least about 35 ⁇ m, or at least about 40 ⁇ m.
  • the average particle size of the coating powder is no more than about 50 ⁇ m, no more than about 45 ⁇ m, no more than about 40 ⁇ m, no more than about 35 ⁇ m, no more than about 30 ⁇ m, no more than about 25 ⁇ m, no more than about 20 ⁇ m, no more than about 15 ⁇ m, no more than about 10 ⁇ m, no more than about 5 ⁇ m, no more than about 4 ⁇ m, no more than about 3 ⁇ m, no more than about 2 ⁇ m, or no more than about 1 ⁇ m.
  • compositions described herein include a sorbent material.
  • This sorbent material is intended to absorb or adsorb moisture from the environment, thus reducing the exposure of the aerosol-generating material to moisture, thus reducing the absorption of moisture by the aerosol-generating material prior to its use.
  • the competition between the aerosol-generating material and the sorbent material for moisture means that the amount of moisture absorbed by the aerosol-generating material is reduced.
  • the sorbent material is more hygroscopic than the aerosol-generating material.
  • the Dynamic Vapour Sorption is a gravimetric technique that may be used to measure how quickly a sample of a material absorbs water by varying the vapour concentration surrounding the sample and measuring the change in mass which this produces. DVS may be used to measure of the rate of water uptake of both the sorbent material and the aerosol-generating material. In preferred embodiments, the rate of water uptake of the sorbent material preferably being greater than that of the aerosol-generating material.
  • the rate of water uptake of the sorbent material is preferably greater than that of the aerosol-generating material at or above about 20% RH, above about 30% RH, above about 40% RH or above about 50% RH.
  • the sorbent material not only absorbs or adsorbs moisture, but will also prevent the release of this water (as vapour) in a manner that may interfere with the desired aerosol being generated by heating the aerosol-generating material. Therefore, in some embodiments, the sorbent holds onto the captured moisture whilst the aerosol-generating material is heated to form an aerosol. Thus, in some embodiments, the sorbent material holds the absorbed or adsorbed moisture at a temperature of up to about 200° C., about 250° C., about 300° C., up to about 325° C., or up to about 350° C. In other embodiments, the sorbent releases the water at a temperature of from about 100° C. to about 150° C., so that it releases the water at a temperature below that at which the first puff of aerosol for inhalation by the consumer will be generated.
  • the sorbent material is a desiccant.
  • the composition comprises the sorbent material on the surface of the agglomerated aerosol-generating material.
  • the sorbent material may form a partial or incomplete coating surrounding the agglomerate.
  • the partial or incomplete coating means that the aerosol generated by heating the aerosol-generating material can be released from the composition and is available for inhalation.
  • the partial coating is in the form or a permeable network. This ensures that the sorbent is present on the surface of the agglomerated aerosol-generating material, but that it does not prevent the volatiles generated by heating the aerosol-generating material being released.
  • the sorbent particles have an average size of no more than about 3 mm, no more than about 2.5 mm, no more than about 2 mm, no more than about 1.5 mm, no more than about 1 mm, no more than about 900 ⁇ m, no more than about 800 ⁇ m, no more than about 700 ⁇ m, no more than about 600 ⁇ m, or no more than about 500 ⁇ m.
  • the composition comprises an agglomerate formed from one or more particles of aerosol-generating material and one or more particles of a sorbent material.
  • the sorbent may be present on or at the surface of the agglomerate, or the sorbent may be more concentrated at the surface.
  • the agglomerates of aerosol-generating material and sorbent material have an average size from about 3 mm to about 20 mm.
  • the amount of sorbent material included in the composition is at least about 5% based on the total weight of the composition, at least about 10%, at least about 15%, at least about 20%, at least about 25% or at least about 30%.
  • the amount of sorbent material included in the composition is no more than about 50% based on the total weight of the composition, no more than about 45%, no more than about 40%, no more than about 35%, no more than about 30%, no more than about 25% or no more than about 20%.
  • the amount of the sorbent to be included may be limited by the potential swelling of the sorbent material as it absorbs moisture. This increase in size of the sorbent will increase the volume of the composition comprising the aerosol-generating material and sorbent material. In extreme circumstances, where large amounts of sorbent are included in the composition and in an environment with a high level of moisture, the expansion of the sorbent may cause issues such as the consumable no longer fitting onto the aerosol-provision device, or the airflow through the composition being reduced and the release of the aerosol being compromised.
  • the aerosol-generating material comprises a dried extract from a flavour- and/or active-containing plant material.
  • the aerosol-generating material further comprises an aerosol-former material.
  • the drying process is selected to retain the desired components of the precursor material and, therefore, the aerosol-generating material may comprise one or more active substances and/or flavours.
  • the aerosol-generating materials also have the advantage of having a high concentration of the desired components. This means that relatively small amounts of the aerosol-generating material are required and less energy is required to heat and release the desired components. Significantly, the aerosols generated from these materials also provide an authentic tobacco taste of reasonable strength.
  • the extract from a flavour- or active-substance containing plant material is an extract derived from tobacco material.
  • the tobacco extract or material may be from or may be any type of tobacco and any part of the tobacco plant, including tobacco lamina, stem, stalk, ribs, scraps and shorts or mixtures of two or more thereof. Suitable tobacco extracts or materials include the following types: Virginia or flue-cured tobacco, Burley tobacco, Oriental tobacco, or blends of tobacco materials, optionally including those listed here.
  • the tobacco may be expanded, such as dry-ice expanded tobacco (DIET), or processed by any other means.
  • the tobacco material may be reconstituted tobacco material.
  • the tobacco may be pre-processed or unprocessed, and may be, for instance, solid stems (SS); shredded dried stems (SDS); steam treated stems (STS); or any combination thereof.
  • the precursor material which is dried to form the aerosol-generating material may comprise at least about 10 wt %, at least about 15 wt %, at least about 20 wt %, at least about 25 wt %, at least about 30 wt %, at least about 35 wt %, or at least about 40 wt % tobacco solids (calculated on a wet weight basis). Additionally or alternatively, the precursor material may comprise up to about 60 wt %, up to about 55 wt %, up to about 50 wt %, up to about 45 wt %, or up to about 40 wt % tobacco solids (calculated on a wet weight basis). In some embodiments, the precursor material comprises from about 20 wt % to about 40 wt % tobacco solids (calculated on a wet weight basis).
  • the precursor material comprises at least about 10 wt %, about 20 wt %, at least about 30 wt %, at least about 40 wt %, at least about 50 wt %, at least about 60 wt %, at least about 70 wt %, at least about 80 wt %, or at least about 90 wt % extract from a tobacco or other flavour- or active-substance containing plant material (calculated on a wet weight basis).
  • precursor material may comprise up to about 99 wt %, up to about 90 wt %, up to about 80 wt %, up to about 70 wt % or up to about 60 wt % extract from tobacco or other flavour- or active-substance containing plant material (calculated on a wet weight basis).
  • the precursor material comprises around 50 wt % tobacco extract (calculated on a wet weight basis).
  • the precursor material comprises around 50 v/v % tobacco extract.
  • the precursor material comprises around 50 v/v % tobacco extract and the tobacco extract has a tobacco solid content of between about 55 and about 60 v/v %
  • the overall tobacco solid content of the precursor material is from about 27.5 to about 30 v/v %.
  • the tobacco extract has a solids content of between about 40 and about 65 wt %, between about 45 and about 65 wt %, or between about 40 and about 60 wt % (calculated on a wet weight basis).
  • the water content of the tobacco extract is between about 35 wt % and about 65 wt %, or between about 35 and about 55 wt % (calculated on a wet weight basis).
  • the nicotine content of the tobacco extract is between about 1 wt % and about 5 wt % (calculated on a wet weight basis).
  • the tobacco extract is an aqueous tobacco extract.
  • the tobacco extract may be concentrated and subsequently diluted before being added to the precursor material and dried. In other embodiments, the tobacco extract is not concentrated and may be used directly in the precursor material.
  • the precursor material may be in the form of a slurry, a suspension, a gel, a liquid or a solid, but in some embodiments which may be preferred, it is in the form of a suspension or liquid. In some embodiments, particles of solid material may be removed from the extract and/or from the precursor material by filtration and/or centrifugation.
  • the water content of the precursor material may be at least about 20 wt %, at least about 30 wt %, at least about 40 wt %, at least about 50 wt %, at least about 60 wt %, at least about 70 wt %, at least about 80 wt %, or at least about 90 wt % on a wet weight basis.
  • the water content of the precursor material may be up to about 95 wt %, up to about 90 wt %, up to about 85 wt %, up to about 80 wt %, up to about 75 wt %, up to about 70 wt %, up to about 65 wt %, up to about 60 wt %, up to about 55 wt % or up to about 50 wt % on a wet weight basis.
  • the water content of the precursor material is between about 40 and about 50 wt % on a wet weight basis (50% and 60 v/v %). When the precursor material has a lower water content, the spray/freeze-drying process is quicker, as there is less water to remove.
  • the dried aerosol-generating material and/or the precursor material comprises one or more active substance. This may be derived from the extract or it may be added. In some embodiments, the extract from a flavour- or active-substance containing plant material comprises an active substance.
  • the aerosol-generating material and/or the precursor material comprises one or more cannabinoid compounds selected from the group consisting of: cannabidiol (CBD), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiolic acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabichromene (CBC), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM) and cannabielsoin (CBE), cannabicitran (CBT).
  • CBD cannabidiol
  • THC tetrahydrocannabinol
  • THCA tetrahydroc
  • the aerosol-generating material further comprises an aerosol-former material. In some embodiments, this aerosol-former material is included in the precursor material.
  • the aerosol-former material may comprise one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.
  • a combination of two or more aerosol forming agents may be used, in equal or differing proportions.
  • the aerosol-generating material may comprise from about 17 to about 36 wt % of glycerol.
  • the amount of glycerol in the aerosol material is important because it is both an aerosol-forming material and a plasticizer. If the concentration of glycerol is too high, it may be detrimental to the critical temperature of the product during the freeze-drying process and may result in collapse of the product if a critical temperature of the formulation is exceeded. On the other hand, sufficient glycerol should be included to provide the consumer with an adequate and pleasing aerosol.
  • the precursor material comprises about 50 wt % tobacco extract, from 0 to about 36 wt % aerosol forming agent (for example, from 0 to about 15 v/v %) and from 0 to about 40 wt % (for example, about 37.5 v/v %) excipient.
  • the tobacco extract may comprise about 55 wt % tobacco solids and the overall tobacco solids content of the precursor material is about 27.5 wt %.
  • Some sample formulations of dried aerosol-generating materials formed from aqueous tobacco extracts are summarised in Table 1 below, with the amounts provided on a dry weight basis. These are theoretical values (before drying and inherent losses). Typically from about 80 to 89% of the glycerol is retained following the drying. Glycerol may be used as an aerosol-former material, but can be replaced or partially replaced with one or more other aerosol-former material such as those disclosed herein.
  • the excipient used may be a dextran such as Dextran 70. Again, this may be replaced or partially replaced with alternative excipients, such as those disclosed herein.
  • the aerosol-generating material and/or the precursor material comprises one or more binders.
  • the one or more binder is selected from the group consisting of: thermoreversible gelling agents, such as gelatin; starches; polysaccharides; pectins; celluloses; cellulose derivatives, such as carboxymethylcellulose; and alginates.
  • the aerosol-generating material and/or the precursor material comprises one or more flavour-modifier, flavour or flavourant.
  • flavour-modifier derived from the extract or it may be added.
  • flavourant refers to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers.
  • flavour materials may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot,
  • the aerosol-generating material and/or the precursor material comprises one or more other functional materials, which may comprise one or more of pH regulators, colouring agents, preservatives, fillers, stabilizers, and/or antioxidants.
  • the gelling agent comprises (or is) one or more non-cellulosic gelling agents, including, but not limited to, agar, xanthan gum, gum Arabic, guar gum, locust bean gum, pectin, carrageenan, starch, alginate, and combinations thereof.
  • the non-cellulose based gelling agent is alginate or agar.
  • the aerosol-generating material and/or the precursor material may comprise an acid.
  • the acid may be an organic acid.
  • the acid may be at least one of a monoprotic acid, a diprotic acid and a triprotic acid.
  • the acid may contain at least one carboxyl functional group.
  • the acid may be at least one of an alpha-hydroxy acid, carboxylic acid, dicarboxylic acid, tricarboxylic acid and keto acid.
  • the acid may be an alpha-keto acid.
  • an acid may be beneficial in embodiments in which the aerosol-generating material and/or the precursor material comprises nicotine.
  • the presence of an acid may stabilise dissolved species in the slurry from which the aerosol-generating material is formed.
  • the presence of the acid may reduce or substantially prevent evaporation of nicotine during drying of the slurry, thereby reducing loss of nicotine during manufacturing.
  • the aerosol-generating material comprises a gelling agent comprising a cellulosic gelling agent and/or a non-cellulosic gelling agent, an active substance and an acid.
  • the dried aerosol-generating material may be in any solid form.
  • the aerosol-generating material may be in the form of particles, granules or powder.
  • the aerosol-generating material may be in the form of a monolithic form, tablet, agglomerate or “cake”.
  • the aerosol-generating material formed by freeze- or spray-drying and is then processed with other suitable steps as required and known to the person skilled in the art to provide the dried material in the desired form, for example in the form of particles of the desired size(s).
  • the aerosol-generating material is in the form of granules.
  • the granules may be of any size, cross-sectional shape or mass.
  • the aerosol-generating material in the form of granules is advantageous due to the high surface area to volume ratio, which positively impacts the release of volatiles from the material. This form also facilitates incorporation of the material into an aerosol provision system.
  • Smaller granule particles have a greater surface area to volume ratio and they may therefore exhibit enhanced release of tobacco constituents compared to particles of larger sizes.
  • the particles in the precursor composition may be desirable for the particles in the precursor composition, to have an average particle size of no greater than about 3 mm, of no greater than 1 mm, of no greater than about 0.5 mm, or to have an average particle size of no greater than about 0.3 mm, when measured by sieving.
  • the average particle size is within the range of about 0.1 to about 3 mm, of about 0.1 to about 1 mm, of about 0.1 to about 0.5 mm, of about 0.1 to about 0.4 mm, or in the range of about 0.2 to about 0.3 mm.
  • at least about 90% of the particles of the precursor composition will have a particle size within the range of about 0.1 to about 3 mm, or of about 0.1 to about 1 mm, or of about 0.1 to about 0.5 mm.
  • at least about 90% of the tobacco particles of the precursor composition will have a particle size within the range of about 0.1 to about 3 mm, or of about 0.1 to about 1 mm, or of about 0.1 to 0.5 mm.
  • none of the particles in the precursor composition have a particle size greater than 5 mm, greater than 4 mm, greater than 2 mm, greater than 1.5 mm, or greater than about 1 mm. In some embodiments, the average particle size is less than 1 mm.
  • Particles of the aerosol-generating material of a smaller size may be advantageous for aerosol generation.
  • smaller particles may have a greater surface area to volume ratio, which may improve aerosol generation.
  • the dried aerosol-generating material readily forms particles with an average size of smaller than 1 mm.
  • the particles may be as small as 10 ⁇ m or even as small as 1 ⁇ m. The size of the particles may be determined by sieving or by observing the particles by SEM.
  • the freeze dried precursor material is ground into particles and may be sieved to exclude particles that are considered too small or too large to be used as aerosol-generating material.
  • aerosol-generating material used in the present invention has a particle size distribution D10 from about 5 to about 25 ⁇ m (meaning that 10% of the particles in the tested sample are smaller than the value), a particle size distribution D50 from about 30 to about 200 ⁇ m (meaning that 50% of the particles in the tested sample are smaller than the value), and a particle size distribution D90 from about 500 to about 2500 ⁇ m (meaning that 90% of the particles in the tested sample are smaller than the value).
  • D10 from about 5 to about 25 ⁇ m (meaning that 10% of the particles in the tested sample are smaller than the value)
  • a particle size distribution D50 from about 30 to about 200 ⁇ m (meaning that 50% of the particles in the tested sample are smaller than the value)
  • a particle size distribution D90 from about 500 to about 2500 ⁇ m (meaning that 90% of the particles in the tested sample are smaller than the value).
  • the freeze dried material used as the aerosol-generating material according to the present invention has a particle size distribution D10 from about 8 to about 15 ⁇ m, a particle size distribution D50 from about 50 to about 150 ⁇ m, and a particle size distribution D90 from about 900 to about 1700 ⁇ m.
  • the precursor material is freeze-dried using freeze-drying microscopy, for example using a Lyostat freeze-drying microscope.
  • the precursor material is sprayed and rapidly dried using a hot gas.
  • spray drying provides several advantages to the present invention: the dry particle size can be controlled and may be consistent; tobacco or flavour extracts or materials are heat sensitive but can still be spray-dried at relatively high inlet temperatures; a short residence time in the spray-drying equipment is required; and minimal loss of flavour/volatiles. This makes the process adaptable to reduce loss of volatile compounds and maintain the desired flavour of the aerosol generating material.
  • Freeze-drying also known as lyophilisation or cryodesiccation, is a process in which the precursor material is frozen, the temperature lowered and the water is removed via sublimation under reduced pressure conditions. Without wishing to be bound by any specific theory, it is believed that the low processing temperatures and rapid water loss via sublimation avoid changes in the aerosol-generating material's structure, appearance and characteristics. This process preserves the structure of the precursor material, and reduces the loss and decomposition of volatile flavour compounds.
  • the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system.
  • the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement.
  • END electronic nicotine delivery system
  • the non-combustible aerosol provision system is an aerosol-generating material heating system, also known as a heat-not-burn system.
  • a heat-not-burn system is a tobacco heating system.
  • the non-combustible aerosol provision system may comprise a power source and a controller.
  • the power source may, for example, be an electric power source or an exothermic power source.
  • the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to a composition comprising an agglomerate comprising a plurality of particles of an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source.
  • FIG. 2 shows an example of a non-combustible aerosol provision device 100 for generating aerosol from an aerosol-generating medium/material such as the composition of a consumable 110 , as described herein.
  • the device 100 may be used to heat a replaceable article 110 comprising the aerosol-generating medium, for instance an article 1 as illustrated in FIG. 1 or as described elsewhere herein, to generate an aerosol or other inhalable medium which is inhaled by a user of the device 100 .
  • the device 100 and replaceable article 110 together form a system.
  • the device 100 comprises a housing 102 (in the form of an outer cover) which surrounds and houses various components of the device 100 .
  • the device 100 has an opening 104 in one end, through which the article 110 may be inserted for heating by a heating assembly. In use, the article 110 may be fully or partially inserted into the heating assembly where it may be heated by one or more components of the heater assembly.
  • the device 100 of this example comprises a first end member 106 which comprises a lid 108 which is moveable relative to the first end member 106 to close the opening 104 when no article 110 is in place.
  • the lid 108 is shown in an open configuration, however the lid 108 may move into a closed configuration.
  • a user may cause the lid 108 to slide in the direction of arrow “B”.
  • the device 100 may also include a user-operable control element 112 , such as a button or switch, which operates the device 100 when pressed. For example, a user may turn on the device 100 by operating the switch 112 .
  • a user-operable control element 112 such as a button or switch
  • the device 100 may also comprise an electrical component, such as a socket/port 114 , which can receive a cable to charge a battery of the device 100 .
  • the socket 114 may be a charging port, such as a USB charging port.
  • the substance to be delivered may be a composition comprising an agglomerate comprising particles of aerosol-generating material, and optionally another aerosol-generating material that may or may not be heated.
  • the composition and other aerosol-generating material may comprise one or more active constituents, one or more flavours, one or more aerosol-former materials, and/or one or more other functional materials.
  • the invention enjoys the advantage of longer shelf life than other tobacco extracts.
  • the nicotine content of the precursor and aerosol-generating material after the freeze drying process has been calculated, providing an indication of the amount of nicotine retained following the processing.
  • the nicotine recovery of the dried aerosol generating material is at least about 76 wt % on a dry weight basis.
  • the nicotine recovery of the dried aerosol generating material compared to the original tobacco extract may be at least about 60%, at least about 70%, at least about 75%, at least about 80%, or at least about 90% on a dry weight basis.
  • the glycerol content of the precursor and dried aerosol-generating material after the freeze drying process has been calculated, providing an indication of the amount of glycerol retained following the processing.
  • the glycerol recovery of the dried aerosol generating material is at least about 85%.
  • the glycerol recovery of the dried aerosol generating material compared to the precursor material may be at least about 70%, at least about 75%, at least about 80%, at least about 85%, at least about 90% at least about 95% on a dry weight basis.
  • the precursor material comprised essentially of aqueous tobacco extract, and glycerol.
  • the aqueous tobacco extract was diluted further with glycerol up to about 24 wt % (calculated on a dry weight basis).
  • the Burley aqueous tobacco extract had a tobacco solid content of about 40 wt %, and a water content of about 60 wt %.
  • the precursor material was dried via freeze drying.
  • the precursor material comprised essentially of aqueous tobacco extract, glycerol and Dextran 70.
  • the glycerol content was about 0 to about 15 v/v %, or up to about 36 wt % calculated on a dry weight basis.
  • the precursor material was dried via freeze drying.
  • Example 1 or Example 2 The freeze-dried material of Example 1 or Example 2 is ground to provide a loose powder with an average size of from about 0.1 mm to about 1 mm.
  • the loose powder is then combined with 5 wt % of sodium alginate as a binder, and the mixture undergoes tumble-growth/agitation agglomeration to form agglomerates from the powder. This results in agglomerates with a high surface area, high porosity and low density.
  • Example 1 or Example 2 The freeze-dried material of Example 1 or Example 2 is ground to provide a loose powder with an average size of from about 0.1 mm to about 1 mm.
  • the loose powder is then combined with 5 wt % of propylene glycol as a binder, and the mixture undergoes tumble-growth/agitation agglomeration to form agglomerates from the powder. This results in agglomerates with a high surface area, high porosity and low density.

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US18/851,550 2022-04-01 2023-03-31 A composition comprising an agglomerate comprising an aerosol-generating material and uses thereof Pending US20250212938A1 (en)

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