The present disclosure provides an aerosol generating component containing a substrate impregnated with one or more aerosol forming materials, the substrate including a cellulosic material substantially free of sulfur compounds, and further including one or more of a tobacco pulp, an aqueous tobacco extract, a filler, and a binder. Further provided is an aerosol delivery device including the aerosol generating component. Such devices utilize electrically generated heat or combustible ignition sources to heat the aerosol forming materials, providing an inhalable substance in the form of an aerosol.

A substrate is provided comprising an aerosol-generating material, the aerosol-generating material comprising a thermoreversible amorphous solid, the thermoreversible amorphous solid comprising: 0.5-20 wt % of iota- and/or kappa-carrageenan; 20-80 wt % of an aerosol-former material; 20-70 wt % of a flavorant and/or an active substance; wherein these weights are calculated on a dry weight basis. Consumables and non-combustible aerosol provision systems comprising the substrate, as well as methods of making and using these, are also provided.

A consumable for use with a non-combustible aerosol provision system, the consumable including a plurality of discrete portions of aerosol-generating material, wherein each of the discrete portions comprises less than about 15 mg water. The aerosol-generating material including an amorphous solid including a percentage of each of a gelling agent, an aerosol-former material, and a flavorant or active substance. The percentages are calculated on a dry weight basis.

The present disclosure provides component-containing extruded structures, which include various components entrapped within a base material matrix, and to products containing such component-containing extruded structures. The disclosure also includes a method for entrapping the components, including mixing the component or components with a base material in water, extruding the mixture, and removing at least a portion of the water therefrom. The resulting component-containing extruded structure can then be incorporated within various products, e.g., consumable products such as aerosol-generating devices and components, oral and smokeless products, and conventional smoking articles.

A non-tobacco oral nicotine pouch composition is provided, including water in an amount of at least 15% by weight of the pouch composition; nicotine; and at least one sugar alcohol, the pouch composition being free of humectants consisting of alginate, propylene glycol, hydroxypropyl cellulose, and glycerol. An oral pouched nicotine product is also provided, including a saliva-permeable pouch and the non-tobacco oral nicotine pouch composition enclosed in the saliva-permeable pouch.

Disclosed herein is an inhalable composition, suitable for use in an electronic cigarette device, comprising at least 1 g/L of nicotine and at least 2 g/L of carbon dioxide dissolved or dispersed in a solvent comprising glycerol and water, wherein the molar ratio of carbon dioxide to nicotine is at least 0.1:1; wherein glycerol is present in an amount of at least 40% by weight, based on the total weight of the inhalable composition; wherein water is present in an amount of 1-20% by weight, based on the total weight of the inhalable composition; and wherein propylene glycol, when present, is present in an amount of no more than 10% by weight, based on the total weight of the inhalable composition.

A method of making an amorphous solid is provided. The method comprises: (a) forming a slurry comprising: 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) setting the slurry to form a gel; and (d) drying the gel to form an amorphous solid; wherein the drying comprises heating the gel to a temperature in the range of about 80° C. to about 140° C. for a period of less than 60 minutes. Amorphous solids provided by the method, articles comprising the amorphous solids, and non-combustible aerosol provision systems comprising the articles are also provided.

An aerosol generating article includes: a first portion comprising an aerosol generating material; a second portion comprising a tobacco material including a moisturizing agent; a third portion configured to cool airflow that has passed through the first portion and the second portion; a fourth portion comprising a filter material; and a wrapper that surrounds the first portion, the second portion, the third portion, wherein the second portion includes the moisturizing agent in an amount of 10 wt % or less based on a total weight of the tobacco material such that heat conductivity in the second portion is improved.

An assembly for generating an inhalable medium, a cartridge for use in an assembly for generating an inhalable medium, a method of generating an inhalable medium, a kit, a liquid pod, and a nicotine-containing pod.

A method for preparing the nicotine-containing powder includes dissolving a carrier in a solvent to form a first solution, where the carrier includes a biopolymer, a natural polymer, a synthetic polymer, a bulk sweetener, or any combination thereof; contacting the first solution with nicotine, a nicotine complex, a nicotine salt, or any combination thereof to form a second mixture; and spray drying the second mixture to form a plurality of particles that define the nicotine-containing powder. The method may further include adding at least one of a pH modifier and an antioxidant to the second mixture. When the solvent includes water, an inlet temperature ranges from 120° C. to 210° C. and an initial product temperature ranges from 25° C. to 100° C. When the solvent includes ethanol, the inlet temperature ranges from 65° C. to 180° C. and an initial product temperature ranges from 25° C. to 79° C.