Abstract: 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.

Abstract: Pellet substrates configured for use with a vapor delivery device to vaporize and deliver an aerosol to a user include a semi-porous base material formed of activated alumina pellets, activated carbon pellets, hulled millet grains that have a generally rounded shape or cellulose paper that has a generally disc shape. The pellet substrates are formed by mixing the base material with a liquid solution of an aerosol former and at least one of a tobacco extract mixture and a tobacco powder blend until the liquid solution is absorbed onto the exposed surfaces of the base material with or without drying by applying heat. The base material may be coated with a liquid hydrocolloid gum solution, namely a water soluble gum, such as sodium carboxymethyl cellulose, and distilled water to reduce fracturing, cracking, chipping and dusting of the pellet substrates.

Abstract: Pellet substrates configured for use with a vapor delivery device to vaporize and deliver an aerosol to a user include a semi-porous base material formed of activated alumina pellets, activated carbon pellets, hulled millet grains that have a generally rounded shape or cellulose paper that has a generally disc shape. The pellet substrates are formed by mixing the base material with a liquid solution of an aerosol former and at least one of a tobacco extract mixture and a tobacco powder blend until the liquid solution is absorbed onto the exposed surfaces of the base material with or without drying by applying heat. The base material may be coated with a liquid hydrocolloid gum solution, namely a water soluble gum, such as sodium carboxymethyl cellulose, and distilled water to reduce fracturing, cracking, chipping and dusting of the pellet substrates.

Abstract: Pellet substrates configured for use with a vapor delivery device to vaporize and deliver an aerosol to a user include porous, substantially inert activated carbon and activated alumina pellets that have generally spherical, semi-spherical and/or rounded shapes. The pellet substrates are formed by mixing the pellets together with a liquid solution of an aerosol former admixed with flavoring and/or nicotine, tobacco powder, or tobacco extract such that the liquid solution is absorbed into and/or adsorbed onto the porous structure of the pellets with or without the addition of heat. The pellets may be coated with an inert dry powder, such as calcium carbonate, to better adhere the liquid solution to the porous surfaces of the pellets. Alternatively, or in addition, the pellets may be coated with a liquid solution of a cellulose gum, such as sodium carboxymethylcellulose, and distilled water to reduce fracturing, cracking, chipping and dusting of the pellet substrates.

Abstract: Pellet substrates configured for use with a vapor delivery device to vaporize and deliver an aerosol to a user include porous, substantially inert activated carbon and activated alumina pellets that have generally spherical, semi-spherical and/or rounded shapes. The pellet substrates are formed by mixing the pellets together with a liquid solution of an aerosol former admixed with flavoring and/or nicotine, tobacco powder, or tobacco extract such that the liquid solution is absorbed into and/or adsorbed onto the porous structure of the pellets with or without the addition of heat. The pellets may be coated with an inert dry powder, such as calcium carbonate, to better adhere the liquid solution to the porous surfaces of the pellets. Alternatively, or in addition, the pellets may be coated with a liquid solution of a cellulose gum, such as sodium carboxymethylcellulose, and distilled water to reduce fracturing, cracking, chipping and dusting of the pellet substrates.

Abstract: A cigarette includes lighting and mouth ends. It may include a smokable segment disposed at the lighting end. It also includes a mouth-end segment; an aerosol-generation system disposed between the lighting and mouth ends, which includes (i) a heat-generation segment adjacent the smokable segment, including a heat source and an insulation layer and (ii) an aerosol-generating segment including a substrate, which may include tobacco pellets and aerosol-forming material disposed in a substrate cavity between the heat generation segment and the mouth end; a piece of outer wrapping material that provides an overwrap around at least a portion of the aerosol-generating segment, the heat-generation segment, and at least a portion of the smokable segment and includes a foil strip laminated thereon; those segments being connected together by the overwrap to provide a cigarette rod; that is connected to the mouth-end segment using tipping material.

Abstract: A cigarette includes lighting and mouth ends. It may include a smokable segment disposed at the lighting end. It also includes a mouth-end segment; an aerosol-generation system disposed between the lighting and mouth ends, which includes (i) a heat-generation segment adjacent the smokable segment, including a heat source and an insulation layer and (ii) an aerosol-generating segment including a substrate, which may include tobacco pellets and aerosol-forming material disposed in a substrate cavity between the heat generation segment and the mouth end; a piece of outer wrapping material that provides an overwrap around at least a portion of the aerosol-generating segment, the heat-generation segment, and at least a portion of the smokable segment and includes a foil strip laminated thereon; those segments being connected together by the overwrap to provide a cigarette rod; that is connected to the mouth-end segment using tipping material.

Abstract: Substrates configured for use with an aerosol agent delivery device to vaporize and deliver an aerosol agent to a user include a carrier and a paste applied to the carrier. The carrier is formed from a non-combustible, thermally conductive, non-toxic and non-off gassing material, such as glass, ceramic or metal. The carrier may be formed in the shape of a solid or porous disc, cupped disc, cylinder or spiral cylinder and the paste may be applied to at least one surface of the carrier. The paste composition may include a binder material, an aerosol agent, such as a therapeutic drug or nicotine, an aerosol forming agent, and an inorganic, inert filler material. The aerosol agent may be derived from an organic plant material, such as ground tobacco, coffee, tea or the like. The aerosol agent may also be provided as a liquid additive, such as liquid nicotine and tobacco flavor.

Abstract: A device for vaporizing and delivering an aerosol agent includes a heat generator, a heat conductor in fluid (airflow) communication with the heat generator, and a substrate holder in heat conducting relation with the heat conductor. The heat generator is a handheld, portable torch and the heat conductor defines an annular heat conducting chamber surrounding a substrate disposed within the substrate holder that supports the aerosol agent and an aerosol forming agent. Another device is a handheld, battery-powered heat generator including a heating element in heat conducting relation with a substrate holder. The heating element is a nichrome heating coil wound about the substrate disposed within the substrate holder and electrically coupled to the battery. Another device further includes an auxiliary heat generator having an auxiliary heating element formed by a finely woven wire mesh positioned adjacent the substrate and electrically coupled to the battery.

Abstract: A device for vaporizing and delivering an aerosol agent includes a heat generator, a heat conductor in fluid (airflow) communication with the heat generator, and a substrate holder in heat conducting relation with the heat conductor. The heat generator is a handheld, portable torch and the heat conductor defines an annular heat conducting chamber surrounding a substrate disposed within the substrate holder that supports the aerosol agent and an aerosol forming agent. Another device is a handheld, battery-powered heat generator including a heating element in heat conducting relation with a substrate holder. The heating element is a nichrome heating coil wound about the substrate disposed within the substrate holder and electrically coupled to the battery. Another device further includes an auxiliary heat generator having an auxiliary heating element formed by a finely woven wire mesh positioned adjacent the substrate and electrically coupled to the battery.

Abstract: A device and method for delivering a therapeutic drug to a patient in the form of an aerosol includes a heat generating chamber and an aerosol forming chamber separated by a heat conductor. A heating element is disposed within the heat generating chamber in heat conducting relation with the heat conductor. A substrate having a therapeutic drug and an aerosol forming agent deposited thereon is disposed within the aerosol forming chamber in heat conducting relation with the heat conductor. The heating element ignites a fuel source consisting essentially of a combustible liquefied gas to generate heat that is conducted to the heat conductor and then to the substrate via the heat conductor. The heat generated by the heating element activates the aerosol forming agent to volatilize the therapeutic drug into an aerosol drug contained within the aerosol forming chamber and made available to be inhaled by the patient.

Abstract: A device and method for delivering a therapeutic drug to a patient in the form of an aerosol includes a heat generating chamber and an aerosol forming chamber separated by a heat conductor. A heating element is disposed within the heat generating chamber in heat conducting relation with the heat conductor. A substrate having a therapeutic drug and an aerosol forming agent deposited thereon is disposed within the aerosol forming chamber in heat conducting relation with the heat conductor. The heating element ignites a fuel source consisting essentially of a combustible liquefied gas to generate heat that is conducted to the heat conductor and then to the substrate via the heat conductor. The heat generated by the heating element activates the aerosol forming agent to volatilize the therapeutic drug into an aerosol drug contained within the aerosol forming chamber and made available to be inhaled by the patient.

Abstract: A smoking article and methods of making the article are described in which a sheet of reconstituted tobacco having an area less than about 100 cm.sup.2 is manually or machine folded into a substantially flat strip of tobacco for smoking. The reconstituted tobacco sheet may be folded about other folded or unfolded strips of tobacco sheet and compressed into a substantially flat smoking article.

Abstract: The present invention provides improved cigarettes and other smoking articles employing short fuel elements and physically separate aerosol generating means wherein the fuel element is provided with an improved insulating means comprising extremely fine gauge (e.g., about 0.002 inch diameter) wire, woven into a cloth-like material of about 200 mesh.

Abstract: This invention provides improvements in tobacco expansion processes which are capable of dramatically improving tobacco throughput in high pressure tobacco impregnation systems. In accordance with various aspects of the invention, tobacco can be impregnated in a high pressure impregnation zone and removed from the zone for expansion in complete cycle times of less than one minute, typically less than about 15-30 seconds. In addition, tobacco throughputs are further improved in accordance with other aspects of the invention by achieving dramatically improved use of the available treatment space in a high pressure impregnation zone. In addition, the invention provides processes for minimizing the amount of expansion agent used to treat tobacco.

Abstract: A tobacco composition includes a tobacco extract and an edible carrier. The composition allows tobacco to be enjoyed orally.

Abstract: A process for providing a flavorable composition for use as a food condiment is provided. The composition is provided by extracting a mixture of steak sauce ingredients to provide a steak sauce extract separated from the extracted mixture of steak sauce ingredients. The steak sauce extract is heated in a pressure-controlled environment to above ambient pressure at a temperature above about 100.degree. C. The heat treated extract is then contacted with a substrate which is subsequently ground into powder form to provide a dry, powdered condiment useful as a steak sauce.

Abstract: Flavorful tobacco extracts are provided by subjecting a moist spray dried tobacco extract to heat treatment. The moist extract is contacted with a furanone, a pyranone or an alpha-dicarbonyl compound, and exposed to a temperature above about 100.degree. C. in a pressure controlled vessel. Resulting flavorful extracts are useful as forms of tobacco in cigarettes and other smoking articles.

Abstract: Smokable and/or combustible tobacco material is provided by altering the character of tobacco material.Tobacco material is extracted using a solvent to provide a tobacco extract within the solvent and an extracted tobacco material. The extracted tobacco material is separated from at least a portion of the extract and solvent. The extracted tobacco material is subjected to pyrolysis conditions to provide a pyrolyzed material. The pyrolysis conditions can include a temperature of from about 300.degree. C. to about 1250.degree. C. and a non-oxidizing atmosphere.The pyrolyzed material can then be formed into a predetermined shape such as by extrusion, casting and the like.

Abstract: Cigarettes which heat but do not burn tobacco are described, preferably having a carbonaceous fuel element extruded around a physically separate aerosol generating means, comprising an aerosol forming material. These cigarettes are capable of producing substantial quantities of aerosol, both initially and over the useful life of the article, without significant thermal degradation of the aerosol former and without the presence of substantial pyrolysis or incomplete combustion products. Preferably, a barrier member is provided to substantially prevent fluid flow between the aerosol generating means and the fuel element. The barrier member is disposable as the cigarette burns back.Also described are embodiments wherein the aerosol generating means encircles at least a portion of the extruded fuel element.In addition, apparatus and method for making smoking articles are described.