Fire-cured tobacco extract and tobacco products made therefrom

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.

1 .- 24 . (canceled) 
     
     
         25 . An aerosol-generating device, comprising a cartridge containing a composition, the composition comprising an aerosol-forming material and an extract of a fire-cured tobacco material, wherein the device is configured to generate flavored vapor, visible aerosol, or a mixture of flavored vapor and visible aerosol from the composition. 
     
     
         26 . The aerosol-generating device of  claim 25 , wherein the extract is an aqueous extract. 
     
     
         27 . The aerosol-generating device of  claim 25 , wherein the device exhibits the desirable sensory characteristics of fire-cured tobacco and reduced content of benzo[s]pyrene as compared with an aerosol-generating device containing fire-cured tobacco. 
     
     
         28 . The aerosol-generating device of  claim 25 , wherein the concentration of benzo[a]pyrene in the extract is no more than about 10 ppb. 
     
     
         29 . The aerosol-generating device of  claim 25 , wherein the concentration of benzo[a]pyrene in the extract is no more than about 5 ppb. 
     
     
         30 . The aerosol-generating device of  claim 25 , further comprising a tobacco material as a carrier for the extract. 
     
     
         31 . The aerosol-generating device of  claim 25 , further comprising a non-tobacco material as a carrier for the extract. 
     
     
         32 . The aerosol-generating device of  claim 25 , wherein the extract exhibits sensory attributes associated with a fire-cured tobacco material. 
     
     
         33 . The aerosol-generating device of  claim 25 , wherein the extract is present in an amount of about 25% weight percent or less, based on a total dry weight of the liquid. 
     
     
         34 . A method of providing an aerosol or vapor from an aerosol-generating device with a smoky aroma and/or flavor, comprising incorporating an extract of a fire-cured tobacco material within a composition contained in a cartridge of the aerosol-generating device, wherein the device is configured to generate flavored vapor, visible aerosol, or a mixture of flavored vapor and visible aerosol from the composition. 
     
     
         35 . The method of  claim 34 , wherein the extract is incorporated in the liquid in an amount of no more than about 25 weight percent based on a total dry weight of the liquid. 
     
     
         36 . The method of  claim 34 , wherein the extract is an aqueous extract. 
     
     
         37 . The method of  claim 34 , wherein the extract is incorporated in the form of a spray dried or freeze dried extract. 
     
     
         38 . The method of  claim 34 , wherein the extract is incorporated in the form of an impregnated material, comprising a tobacco material as a carrier for the extract. 
     
     
         39 . The method of  claim 34 , wherein the extract is incorporated in the form of an impregnated material, comprising a non-tobacco material as a carrier for the extract. 
     
     
         40 . The method of  claim 34 , wherein the concentration of benzo[a]pyrene in the extract is no more than about 10 ppb. 
     
     
         41 . The method of  claim 34 , wherein the concentration of benzo[a]pyrene in the extract is no more than about 5 ppb. 
     
     
         42 . A method, comprising:
 mixing a cured tobacco material having a first benzo[a]pyrene concentration with a polar protic solvent to produce a slurry, the slurry providing intimate contact between the cured tobacco material and the polar protic solvent;   maintaining the slurry for a time and at a temperature sufficient to form an extract comprising components of the cured tobacco material soluble in the polar protic solvent, the extract exhibiting a second benzo[a]pyrene concentration lower than the first benzo[a]pyrene concentration;   separating the extract from a residual pulp material comprising components of the cured tobacco material that are insoluble in the polar protic solvent; and   incorporating the extract into a composition contained within a cartridge for an aerosol-generating device.   
     
     
         43 . The method of  claim 42 , further comprising applying the separated extract to a tobacco material to form a treated material, and incorporating the extract in the form of the treated material into the composition. 
     
     
         44 . The method of  claim 42 , further comprising applying the separated extract to a non-tobacco material to form a treated material, and incorporating the extract in the form of the treated material into the composition.