Abstract: The present disclosure relates to aerosol delivery devices, methods of forming such devices, and elements of such devices. In some embodiments, the present disclosure provides a heating member that can be formed of a heating element conformed to a heater substrate configured as a truncated cone (or similar shape) having a first end of a first size and a second end of greater size. In some embodiments, the disclosure provides methods of forming an aerosol delivery device, which can include providing a shell, providing a heating member formed of a heating element conformed to a substrate, configuring the heating member as a truncated cone (or similar shape) having a first end of a first size and a second end of greater size, and inserting the heating member within the shell.

Abstract: The invention provides a smokeless tobacco composition adapted for oral use, the composition including a tobacco material and an effervescent material. The effervescent material includes a sugar material containing an entrapped gaseous component, such that release of the entrapped gaseous component occurs upon dissolution of the sugar material in the oral cavity. The invention also provides a method for making a smokeless tobacco composition that involves mixing a tobacco material with an effervescent material, the mixing step including either admixing a granulated composition comprising a tobacco material with a gasified sugar material in particulate form, or forming a gasified sugar material in situ by mixing a water source with a molten composition comprising a tobacco material and a sugar alcohol.

Abstract: The present disclosure relates to aerosol delivery devices, methods of forming such devices, and elements of such devices. In some embodiments, the present disclosure provides a heating member that can be formed of a heating element conformed to a heater substrate configured as a truncated cone (or similar shape) having a first end of a first size and a second end of greater size. In some embodiments, the disclosure provides methods of forming an aerosol delivery device, which can include providing a shell, providing a heating member formed of a heating element conformed to a substrate, configuring the heating member as a truncated cone (or similar shape) having a first end of a first size and a second end of greater size, and inserting the heating member within the shell.

Abstract: The present disclosure relates to aerosol delivery devices and related methods of delivering aerosol to a user. The aerosol delivery devices may include a housing providing multiple aerosol pathways having a mouth-end opening through which aerosol can be inhaled by a user, the housing defining a first aerosol delivery pathway in fluid communication with the mouth-end opening and a second aerosol delivery pathway separate from the first aerosol delivery pathway and in fluid communication with the mouth-end opening. An atomizer including a heating element or piezoelectric element and a liquid transport element in fluid communication with an aerosol precursor composition is provided in fluid communication with the first aerosol delivery pathway. A flavorant-infused material is positioned within the second aerosol delivery pathway and adapted to produce a second aerosol upon contact between the flavorant-infused material and flowing air.

Abstract: The present disclosure relates to aerosol delivery devices. The aerosol delivery devices may include a reservoir containing a liquid aerosol precursor composition and an atomizer including an electrical resistance heating element and a nonfibrous liquid transport element having a microtextured surface adapted for surface wicking of the liquid aerosol precursor composition across the microtextured surface, the microtextured surface of the liquid transport element being in fluid communication with the reservoir and in fluid communication with the electric resistance heating element.

Abstract: The present disclosure relates to an aerosol delivery device that includes a reservoir housing that defines a mouthpiece channel. The aerosol delivery device includes a sealing member configured to be received within the reservoir housing to define a reservoir chamber configured to retain an aerosol precursor composition therein. The aerosol delivery device also includes a substrate member that is configured to be received within the reservoir housing and to be directly engaged with a vaporizing assembly for forming an aerosol. The reservoir housing, sealing member, substrate member, and/or vaporizing assembly can be used for forming aerosols with precise and reproducible compositions.

Abstract: The present disclosure relates to aerosol delivery devices and related methods of delivering aerosol to a user. The aerosol delivery devices may include a housing providing multiple aerosol pathways having a mouth-end opening through which aerosol can be inhaled by a user, the housing defining a first aerosol delivery pathway in fluid communication with the mouth-end opening and a second aerosol delivery pathway separate from the first aerosol delivery pathway and in fluid communication with the mouth-end opening. An atomizer including a heating element or piezoelectric element and a liquid transport element in fluid communication with an aerosol precursor composition is provided in fluid communication with the first aerosol delivery pathway. A flavorant-infused material is positioned within the second aerosol delivery pathway and adapted to produce a second aerosol upon contact between the flavorant-infused material and flowing air.

Abstract: The present disclosure relates to aerosol delivery devices. The aerosol delivery devices may include a reservoir containing a liquid aerosol precursor composition and an atomizer including an electrical resistance heating element and a nonfibrous liquid transport element having a microtextured surface adapted for surface wicking of the liquid aerosol precursor composition across the microtextured surface, the microtextured surface of the liquid transport element being in fluid communication with the reservoir and in fluid communication with the electric resistance heating element.

Abstract: A pouched product adapted for release of a water-soluble component therefrom is provided herein. The pouched product can include an outer water-permeable pouch defining a cavity containing a composition that includes a water-soluble component capable of being released through the water-permeable pouch and has a surface area, wherein the outer water-permeable pouch can include a nonwoven web including a plurality of heat sealable binder fibers blended with a second plurality of dissimilar fibers. The nonwoven web can be carded, hydroentangled and point bonded.

Abstract: The present disclosure relates to an aerosol delivery device that includes a reservoir housing that defines a mouthpiece channel. The aerosol delivery device includes a sealing member configured to be received within the reservoir housing to define a reservoir chamber configured to retain an aerosol precursor composition therein. The aerosol delivery device also includes a substrate member that is configured to be received within the reservoir housing and to be directly engaged with a vaporizing assembly for forming an aerosol. The reservoir housing, sealing member, substrate member, and/or vaporizing assembly can be used for forming aerosols with precise and reproducible compositions.

Abstract: The present disclosure relates to an aerosol delivery device that includes a reservoir housing that defines a mouthpiece channel. The aerosol delivery device includes a sealing member configured to be received within the reservoir housing to define a reservoir chamber configured to retain an aerosol precursor composition therein. The aerosol delivery device also includes a substrate member that is configured to be received within the reservoir housing and to be directly engaged with a vaporizing assembly for forming an aerosol. The reservoir housing, sealing member, substrate member, and/or vaporizing assembly can be used for forming aerosols with precise and reproducible compositions.

Abstract: A pouched product adapted for release of a water-soluble component therefrom is provided herein. The pouched product can include an outer water-permeable pouch defining a cavity containing a composition that includes a water-soluble component capable of being released through the water-permeable pouch and has a surface area, wherein the outer water-permeable pouch can include a nonwoven web including a plurality of heat sealable binder fibers blended with a second plurality of dissimilar fibers. The nonwoven web can be carded, hydroentangled and point bonded.

Abstract: The present disclosure relates to an aerosol delivery device that includes a reservoir housing that defines a mouthpiece channel. The aerosol delivery device includes a sealing member configured to be received within the reservoir housing to define a reservoir chamber configured to retain an aerosol precursor composition therein. The aerosol delivery device also includes a substrate member that is configured to be received within the reservoir housing and to be directly engaged with a vaporizing assembly for forming an aerosol. The reservoir housing, sealing member, substrate member, and/or vaporizing assembly can be used for forming aerosols with precise and reproducible compositions.

Abstract: The present disclosure relates to a microfluidic vaporizer, an aerosol delivery device that may include such vaporizer, and methods for forming an aerosol. A microfluidic vaporizer can comprise a substrate that defines: a reservoir configured to hold a liquid; a heater adapted to vaporize the liquid; and a capillary channel configured for movement of the liquid from the reservoir to the heater. An aerosol delivery device can comprise a shell and a microfluidic vaporizer. The microfluidic vaporizer and aerosol delivery device can be used for forming aerosols with precise and reproducible compositions.

Abstract: The invention provides a tobacco product including a flavorful tobacco composition in the form of an extract of a fire-cured tobacco material. Exemplary tobacco products include smoking articles, smokeless tobacco compositions, and aerosol-generating devices that do not burn tobacco. The invention also provides a process for preparing a smokeless tobacco composition, the method including: mixing a fire-cured tobacco material having a first benzo[a]pyrene concentration with water to produce an aqueous slurry; maintaining the slurry for a time and at a temperature sufficient to form a fire-cured tobacco extract, the aqueous fire-cured tobacco extract exhibiting a second benzo[a]pyrene concentration lower than the first benzo[a]pyrene concentration; separating the aqueous fire-cured tobacco extract from a residual pulp material, and mixing the aqueous fire-cured tobacco extract with a tobacco or non-tobacco plant material to form a smokeless tobacco composition.

Abstract: The present disclosure relates to a microfluidic vaporizer, an aerosol delivery device that may include such vaporizer, and methods for forming an aerosol. A microfluidic vaporizer can comprise a substrate that defines: a reservoir configured to hold a liquid; a heater adapted to vaporize the liquid; and a capillary channel configured for movement of the liquid from the reservoir to the heater. An aerosol delivery device can comprise a shell and a microfluidic vaporizer. The microfluidic vaporizer and aerosol delivery device can be used for forming aerosols with precise and reproducible compositions.

Abstract: A pouched product adapted for release of a water-soluble component therefrom is provided herein. The pouched product can include an outer water-permeable pouch defining a cavity containing a composition that includes a water-soluble component capable of being released through the water-permeable pouch and has a surface area, wherein the outer water-permeable pouch can include a nonwoven web including a plurality of heat sealable binder fibers blended with a second plurality of dissimilar fibers. The nonwoven web can be carded, hydroentangled and point bonded.

Abstract: A pouched product configured for insertion into the mouth of a user of that product is provided herein. The pouched product can include an outer water-permeable pouch defining a cavity containing a composition adapted for oral use and having a surface area, wherein the outer water-permeable pouch can include a nonwoven web including a first plurality of continuous filament heat sealable binder fibers oriented substantially parallel to each other in a first direction, a second plurality of continuous filament heat sealable binder fibers oriented substantially parallel to each other in a second direction, wherein the first direction and the second direction are substantially perpendicular to each other, and wherein the first plurality of continuous filament heat sealable binder fibers and the second plurality if continuous filament heat sealable binder fibers are bonded with a heated lamination process.

Abstract: The invention provides a smokeless tobacco composition adapted for oral use, the composition including a tobacco material and an effervescent material. The effervescent material includes a sugar material containing an entrapped gaseous component, such that release of the entrapped gaseous component occurs upon dissolution of the sugar material in the oral cavity. The invention also provides a method for making a smokeless tobacco composition that involves mixing a tobacco material with an effervescent material, the mixing step including either admixing a granulated composition comprising a tobacco material with a gasified sugar material in particulate form, or forming a gasified sugar material in situ by mixing a water source with a molten composition comprising a tobacco material and a sugar alcohol.

Abstract: A pouched product adapted for release of a water-soluble component therefrom is provided herein. The pouched product can include an outer water-permeable pouch defining a cavity containing a composition that includes a water-soluble component capable of being released through the water-permeable pouch and has a surface area, wherein the outer water-permeable pouch can include a nonwoven web including a plurality of heat sealable binder fibers blended with a second plurality of dissimilar fibers. The nonwoven web can be carded, hydroentangled and point bonded.