An amorphous solid and related methods of making an amorphous solid including: (a) forming a slurry having: 0.5-60 wt % of a gelling agent; 5-80 wt % of an aerosol forming material; and 0-60 wt % of an active constituent and/or flavorant; wherein these weights are calculated on a dry weight basis; (b) shaping the slurry; (c) applying a setting agent to a surface of the slurry so that the slurry sets to form a gel; and (d) drying the gel to form an amorphous solid; wherein the amorphous solid has a substantially constant concentration of setting agent throughout.

A pouched product including an outer water-permeable pouch defining a cavity and a composition configured for oral use situated within the cavity is provided. The composition is at least partially orally dissolvable, and includes one or more dissolvable fillers in an amount of at least about 45% by weight, based on the total weight of the composition; a humectant in an amount up to about 25% by weight, based on the total weight of the composition; and at least one active ingredient, at least one flavorant, or both at least one active ingredient and at least one flavorant.

A flavor-containing sheet for a smoking article, the sheet comprising a thickening polysaccharide, a flavor, an emulsifier, and a filler.

A method of producing an aerosol-generating element for an aerosol-generating article or system is provided, the method including the steps of: preparing a matrix polymer solution including a matrix-forming polymer in water; adding a plurality of aerosol-generating formulation components to the matrix polymer solution to form an aerosol-generating solution, in which the aerosol-generating formulation components include a polyhydric alcohol and at least one alkaloid or cannabinoid, and in which the aerosol-generating solution includes at least 0.5 percent by weight of the at least one alkaloid or cannabinoid; forming a discrete portion of the aerosol-generating solution; adding the discrete portion of the aerosol-generating solution to a cross-linking solution of multivalent cations to cross-link the matrix-forming polymer; and removing the aerosol-generating element from the cross-linking solution and drying the aerosol-generating element.

An aerosol releasing substrate for use in a heat-not-burn device is air permeable and includes tobacco particles and/or an inhalable agent, which contains at least one of a stimulant and/or a flavor, a gelling agent for gelling the aerosol releasing substrate, a degradation preventing and/or thickening stabilizer, and 30-70% humectant. The aerosol releasing substrate further has a soft granular texture. A method of producing a soft granular aerosol releasing substrate for use in a heat-not-burn device, which is air permeable, includes the steps: a) forming a mixture by mixing tobacco particles and/or an inhalable agent, which contains at least one of a stimulant and/or a flavor, a gelling agent for gelling the aerosol releasing substrate, a degradation preventing and/or thickening stabilizer, and 30-70% humectant, and b) forming a soft granular structure from the mixture.

A method of manufacturing flavorant particles includes melting a food grade wax and a flavorant into a molten wax; solidifying the molten wax; and grinding the solidified molten wax into a plurality of flavorant particles. Another method of manufacturing flavorant particles includes melting a food grade wax and a flavorant into a molten wax, the molten wax having a melting temperature between about 50° C. to about 70° C.; and spray-chilling the molten wax into at least one solid flavorant particle, the solid flavorant particle having a diameter of between about 0.1 mm to about 2.0 mm.

There is disclosed a mouth piece, filter element or cooling element 100 comprising: a longitudinally extending core of filtering material 102; one or more channels 104 extending longitudinally from an end of the core 102; wherein the or each channel 104 has a non-circular transverse cross section which varies in the longitudinal direction by rotating about a longitudinal axis I of the mouth piece, filter element or cooling element 100.

Substrates for use with an aerosol delivery device to vaporize and deliver an aerosol to a user include a base material, an aerosol former and an aerosol agent. In a method for forming the substrates, a mixture of substrate materials is extruded and then spheronized to produce pellet substrates that are generally spherical, substantially spherical or rounded, or in the form of relatively short rods having rounded ends. In another method for forming the substrates, a base material is coated with a first coating and optionally the base material having the first coating thereon is subsequently coated with a second coating so as to produce pellet substrates having a relatively smooth, dry exterior surface. In this manner, the substrates are formable relative to one another and can be easily and readily loaded into and removed from the aerosol delivery device.

An aerosol-generating element for an aerosol-generating article or system is provided, the element including: a solid continuous matrix structure; and an aerosol-generating formulation dispersed within the structure, in which the formulation is trapped within the structure and releasable from the structure upon heating of the element, in which the structure is an alginate matrix, in which the formulation consists of: nicotine from 1% by weight to 4% by weight of a total weight of the element, glycerin from 60% by weight to 80% by weight of the total weight of the element, a carboxylic acid from 0.5% by weight to 4% by weight of the total weight of the element, and balance water, in which the formulation dispersed within the structure is at least about 80% by weight of a total weight of the element, and in which the element includes less than 15% by weight of water.

A process is disclosed for incorporating additives into aerosol-producing substrates. During the process, an additive is incorporated into an infusing liquid. An aerosol-producing filler is submerged in the infusing liquid and the resulting mixture is subjected to reduced pressures that cause the infusing liquid to infuse into the material. The material is dried leaving behind the additive in a controlled amount and uniformly dispersed throughout the material. In one application, cannabidiol is incorporated into a tobacco filler or a hemp filler.