Substrates with multiple aerosol-forming materials for aerosol delivery devices

Abstract

The present disclosure provides an aerosol-generating component comprising a substrate impregnated with two or more aerosol-forming materials, the aerosol-generating component comprising a first aerosol-forming material and a second aerosol-forming material, where the first aerosol-forming material and the second aerosol-forming material are different from each other. The first aerosol-forming material and the second aerosol-forming material each have a different boiling point and / or a different vapor pressure. The disclosed aerosol-generating components may be used in aerosol delivery devices, such as heat-generating but non-combustible (HNB) or electrically heated aerosol delivery devices.

Description

[0001] Public domain

[0002] The present disclosure relates to aerosol generating components, aerosol delivery devices and aerosol delivery systems, such as smoking articles, which utilize electrically generated heat or a combustible ignition source to heat an aerosol-forming material, preferably without significant combustion, to provide an inhalable substance in the form of an aerosol for human consumption. Background Art

[0003] Many smoking articles have been proposed for use over the years as improvements or substitutes to smoking products based on burning tobacco. Some exemplary substitutes include devices in which solid or liquid fuels are burned to transfer heat to tobacco, or a chemical reaction is used to provide the heat source. Other exemplary alternatives use electrical energy to heat tobacco and / or other aerosol-generating substrate materials, such as described in U.S. Pat. No. 9,078,473 to Worm et al., which is incorporated herein by reference in its entirety.

[0004] The point of improvement or substitute of smoking article generally provides the feeling related to smoking cigarette, cigar or pipe, but does not deliver the product of large amount of incomplete combustion and pyrolysis. For this reason, many smoking products, flavor generators and medicated inhalers that use electric energy to evaporate volatile materials or heat volatile materials are proposed, or attempt to provide the feeling of smoking cigarette, cigar or pipe without burning tobacco to a large extent. See, for example, various alternative smoking articles, aerosol delivery devices, heat sources are described in U.S. Patent No. 7,726,320 such as Robinson et al.; and U.S. Patent Application Publication No. 2013 / 0255702 of Griffith et al.; and the background described in U.S. Patent Application Publication No. 2014 / 0096781 of Sears et al., each of which is incorporated herein by reference in its entirety.

[0005] Products that produce the taste and sensation of smoking by electrically heating tobacco, tobacco-derived materials, or other plants or plant-derived materials suffer from inconsistent performance characteristics. For example, some products suffer from inconsistent release of flavoring agents or other inhalable materials, and insufficient loading of aerosol-forming materials on the substrate. Therefore, it is desirable to provide a smoking article that can provide the sensation of smoking a cigarette, cigar, or pipe without burning the substrate material and with favorable performance characteristics.

[0006] Aerosol delivery devices in which a solid fuel (e.g., carbon) is burned to transfer heat to tobacco and aerosol delivery devices that utilize heat generated by electricity have as an aerosol-forming substrate as part of the aerosol generating component. Typically, only one aerosol-forming agent is used in the aerosol-forming substrate. Therefore, the tendency of aerosol formation when the substrate is heated will depend on the boiling temperature or vapor pressure of the aerosol-forming agent. In both types of devices, it is advantageous to provide a substrate comprising a plurality of aerosol-forming agents to allow controlled release of the aerosol over time when the substrate is heated. Summary of the invention

[0007] The present disclosure relates to aerosol generating components and aerosol delivery devices that utilize electrically generated heat or a combustible ignition source to heat a substrate impregnated with two or more aerosol-forming materials to provide an inhalable substance in aerosol form for human consumption.

[0008] Therefore, in one aspect, the present disclosure provides an aerosol generating component comprising a substrate, wherein the substrate is impregnated with two or more aerosol-forming materials, including: a first aerosol-forming material and a second aerosol-forming material, wherein the first aerosol-forming material and the second aerosol-forming material each have a different boiling point and / or a different vapor pressure.

[0009] In some embodiments, the first aerosol-forming material and the second aerosol-forming material are independently selected from the group consisting of water, polyols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, triacetin, and sugar alcohols. In some embodiments, at least one of the first aerosol-generating material and the second aerosol-generating material is a polyol. In some embodiments, the two or more aerosol-generating materials are present in a weight ratio of about 3:1 to about 1:3 of the first aerosol-forming material and the second aerosol-forming material.

[0010] In some embodiments, both the first aerosol-forming material and the second aerosol-forming material are polyols. In some embodiments, the polyol is selected from the group consisting of glycerol, 1,2-propylene glycol, 1,3-propylene glycol, diethylene glycol, triethylene glycol, and combinations thereof. In some embodiments, the polyol is glycerol and 1,2-propylene glycol. In some embodiments, glycerol and 1,2-propylene glycol are present in a weight ratio of about 3:1 to about 1:3. In some embodiments, glycerol and 1,2-propylene glycol are present in a weight ratio of about 1:1.

[0011] In some embodiments, the substrate is also impregnated with at least one other aerosol forming agent. In some embodiments, the at least one other aerosol forming agent is selected from the group consisting of water, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, triacetin, sugar alcohols, terpenes, and combinations thereof.

[0012] In some embodiments, the substrate is also impregnated with flavorants, active ingredients, or a combination thereof. In some embodiments, the active ingredients include tobacco components, non-tobacco botanicals, nicotine components, or a combination thereof. In some embodiments, the active ingredients include nicotine components.

[0013] In some embodiments, the substrate is in particulate form, shredded form, film form, paper processed sheet form, cast sheet form, bead form, granule form, rod form, or extrudate form.

[0014] In some embodiments, the substrate is formed into a substantially cylindrical shape.

[0015] In some embodiments, the substrate includes tobacco-derived fibers, wood-derived fibers, or a combination thereof.

[0016] In some embodiments, the substrate further comprises one or more binding agents. In some embodiments, the one or more binding agents are selected from: alginate / ester, cellulose derivatives, starch, gum, dextran, carrageenan, calcium carbonate or a combination thereof. In some embodiments, the substrate comprises one or more of: calcium carbonate, alginate / ester, one or more cellulose derivatives, starch, wood pulp or tobacco derived fibers.

[0017] In some embodiments, the two or more aerosol-forming materials are present in a weight ratio of about 3: 1 to about 1: 3. In some embodiments, the two or more aerosol-forming materials are glycerol and 1,2-propylene glycol.

[0018] In some embodiments, the substrate comprises: about 0 weight % to about 60 weight % calcium carbonate; about 0 weight % to about 10 weight % alginate; about 0 weight % to about 5 weight % one or more cellulose derivatives; about 0 weight % to about 30 weight % starch; about 0 weight % to about 5 weight % wood pulp; about 0 weight % to about 80 weight % tobacco-derived fibers; and the substrate is impregnated with two or more aerosol-forming materials at a loading amount of about 15 weight % to about 55 weight % based on the total weight of the impregnated substrate.

[0019] In some embodiments, the substrate comprises: about 0 wt % to about 5 wt % calcium carbonate; about 1 wt % to about 5 wt % wood pulp; about 70 wt % to about 80 wt % tobacco-derived fibers; and the substrate is impregnated with two or more aerosol-forming materials at a loading of about 15 wt % to about 25 wt %, based on the total weight of the impregnated substrate.

[0020] In some embodiments, the substrate comprises: about 45 wt % to about 60 wt % calcium carbonate; about 0 wt % to about 10 wt % alginate; about 0 wt % to about 5 wt % one or more cellulose derivatives; about 0 wt % to about 15 wt % starch; about 0 wt % to about 5 wt % wood pulp; about 0 wt % to about 40 wt % tobacco-derived fibers; and the substrate is impregnated with two or more aerosol-forming materials at a loading of about 15 wt % to about 25 wt % based on the total weight of the impregnated substrate.

[0021] In some embodiments, the substrate comprises: about 40 wt % to about 60 wt % calcium carbonate; about 0 wt % to about 10 wt % alginate; about 0 wt % to about 5 wt % one or more cellulose derivatives; about 0 wt % to about 15 wt % starch; about 0 wt % to about 5 wt % wood pulp; about 0 wt % to about 40 wt % tobacco-derived fibers; and the substrate is impregnated with two or more aerosol-forming materials at a loading of about 15 wt % to about 25 wt %, based on the total weight of the impregnated substrate.

[0022] In some embodiments, the substrate comprises: about 5 wt % to about 15 wt % calcium carbonate; about 1 wt % to about 5 wt % one or more cellulose derivatives; about 20 wt % to about 40 wt % starch; about 20 wt % to about 40 wt % tobacco-derived fibers; and wherein the substrate is impregnated with two or more aerosol-forming materials at a loading of about 15 wt % to about 25 wt %, based on the total weight of the impregnated substrate.

[0023] In another aspect, an aerosol generating component is provided, comprising a substrate, wherein the substrate is impregnated with two or more aerosol-forming materials, wherein the two or more aerosol-forming materials impregnated include: a first aerosol-forming material selected from the group consisting of glycerol, 1,2-propylene glycol, 1,3-propylene glycol, diethylene glycol, triethylene glycol, polyethylene glycol, triacetin and combinations thereof; and a second aerosol-forming material selected from the group consisting of polysorbates, sorbitan esters, fatty acids, fatty acid esters, 1,3-propylene glycol, triethylene glycol, polyethylene glycol, triacetin, waxes, terpenes and sugar alcohols; wherein the first aerosol-forming material and the second aerosol-forming material each have a different boiling point, a different vapor pressure or a different boiling point and a different vapor pressure; and wherein the substrate is impregnated with the two or more aerosol-forming materials at a loading amount of about 5 wt % to about 60 wt % based on the total weight of the impregnated substrate.

[0024] In some embodiments, the substrate is impregnated with the two or more aerosol-forming materials at a loading of about 15 wt % to about 30 wt %, based on the total weight of the impregnated substrate.

[0025] In some embodiments, the weight ratio of the first aerosol-forming material to the second aerosol-forming material is about 100:1 to about 1: 100. In some embodiments, the weight ratio of the first aerosol-forming material to the second aerosol-forming material is about 3:1 to about 1:3.

[0026] In some embodiments, the second aerosol-forming material is selected from the group consisting of palmitic acid, polyethylene glycol 400, sorbitan tristearate, polysorbate 80, and combinations thereof.

[0027] In some embodiments, the first aerosol-forming material is glycerol and the second aerosol-forming material is 1,3-propylene glycol, triethylene glycol, palmitic acid, or triacetin. In some embodiments, the first aerosol-forming material is glycerol and the second aerosol-forming material is palmitic acid.

[0028] In some embodiments, the first aerosol-forming material is 1,3-propylene glycol, triethylene glycol, 1,2-propylene glycol, or triacetin, and the second aerosol-forming material is palmitic acid, polyethylene glycol 400, sorbitan tristearate, or polysorbate 80.

[0029] In some embodiments, the substrate is impregnated with glycerol, palmitic acid, and a third aerosol-forming material selected from the group consisting of 1,3-propylene glycol, triethylene glycol, 1,2-propylene glycol, glyceryl triacetate, polyethylene glycol 400, sorbitan tristearate, and polysorbate 80.

[0030] In some embodiments, the substrate is impregnated with a mixture selected from the group consisting of glycerol and palmitic acid; glycerol and 1,3-propylene glycol; glycerol and triethylene glycol; glycerol and triacetin; 1,3-propylene glycol and palmitic acid; 1,3-propylene glycol and polyethylene glycol; 1,3-propylene glycol and polysorbate 80; triethylene glycol and palmitic acid; triethylene glycol and polyethylene glycol; triethylene glycol and polysorbate 80; triacetin and palmitic acid; triacetin and polyethylene glycol; triacetin and polysorbate 80; 1,2-propylene glycol and palmitic acid; 1,2-propylene glycol and polyethylene glycol; and 1,2-propylene glycol and polysorbate 80. In some embodiments, the ratio of aerosol-forming materials in each listed mixture is from about 3:1 to about 1:3.

[0031] In some embodiments, the substrate is impregnated with a mixture comprising glycerol, palmitic acid, and 1,2-propylene glycol.

[0032] In some embodiments, the aerosol generating component further comprises glyceryl triacetate.

[0033] In some embodiments, the substrate further comprises up to about 10% by weight water based on the total dry weight of the impregnated substrate.

[0034] In some embodiments, the substrate comprises tobacco-derived fibers, wood-derived fibers, plant or plant-derived fibers, synthetic fibers, or a combination thereof; and one or more binders. In some embodiments, the one or more binders are selected from: alginates, cellulose derivatives, starches, gums, dextran, carrageenan, calcium carbonate, or a combination thereof.

[0035] In some embodiments, the substrate comprises: from about 40% to about 70% by weight tobacco-derived fibers; from about 10% to about 15% by weight cellulose derivatives; and from about 5% to about 10% by weight wood pulp.

[0036] In some embodiments, the substrate is also impregnated with flavorants, active ingredients, or a combination thereof. In some embodiments, the active ingredients include tobacco components, non-tobacco botanicals, nicotine components, or a combination thereof. In some embodiments, the active ingredients include nicotine components.

[0037] In some embodiments, the substrate is in particulate form, shredded form, film form, paper processed sheet form, cast sheet form, bead form, granule form, rod form, or extrudate form. In some embodiments, the substrate is formed into a substantially cylindrical shape.

[0038] On the other hand, an aerosol delivery device is provided, comprising: an aerosol generating component as disclosed herein; a heat source configured to heat an aerosol-forming material impregnated in a substrate to form an aerosol; and an aerosol path extending from the aerosol generating component to a mouthpiece end of the aerosol delivery device.

[0039] In some embodiments, the heat source comprises an electrically powered heat generating element or a combustible ignition source. In some embodiments, the heat source is a combustible ignition source comprising a carbon-based material. In some embodiments, the heat source is an electrically powered heat generating element. In some embodiments, the aerosol delivery device further comprises a power source electrically connected to the heating element. In some embodiments, the aerosol delivery device further comprises a controller configured to control the power transmitted by the power source to the heating element.

[0040] The present disclosure includes, but is not limited to, the following embodiments.

[0041] Embodiment 1: An aerosol generating component comprising a substrate, wherein the substrate is impregnated with two or more aerosol-forming materials, including: a first aerosol-forming material and a second aerosol-forming material, wherein the first aerosol-forming material and the second aerosol-forming material each have a different boiling point and / or a different vapor pressure.

[0042] Embodiment 2: The aerosol generating component as described in the first embodiment, wherein the first aerosol-forming material and the second aerosol-forming material are independently selected from the following group: water, polyols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, triacetin and sugar alcohols.

[0043] Embodiment 3: The aerosol-generating component as described in the first embodiment or the second embodiment, wherein the two or more aerosol-generating materials are present in a weight ratio of the first aerosol-forming material to the second aerosol-forming material of about 3:1 to about 1:3.

[0044] Embodiment 4: The aerosol-generating component according to any one of Embodiments 1 to 3, wherein at least one of the first aerosol-generating material and the second aerosol-generating material is a polyol.

[0045] Embodiment 5: The aerosol-generating component according to any one of Embodiments 1 to 4, wherein both the first aerosol-forming material and the second aerosol-forming material are polyols.

[0046] Embodiment 6: An aerosol generating component as described in any one of embodiments 1 to 5, wherein the polyol is selected from the group consisting of glycerol, 1,2-propylene glycol (propylene glycol), 1,3-propylene glycol (1,3-propanediol), diethylene glycol, triethylene glycol and combinations thereof.

[0047] Embodiment 7: The aerosol-generating component according to any one of Embodiments 1 to 6, wherein the polyol is glycerol and 1,2-propylene glycol.

[0048] Embodiment 8: The aerosol-generating component of any one of Embodiments 1 to 7, wherein glycerol and 1,2-propylene glycol are present in a weight ratio of about 3:1 to about 1:3.

[0049] Embodiment 9: The aerosol-generating component of any one of Embodiments 1 to 8, wherein glycerol and 1,2-propylene glycol are present in a weight ratio of about 1:1.

[0050] Embodiment 10: The aerosol-generating component of any one of Embodiments 1 to 9, wherein the substrate is further impregnated with at least one other aerosol-forming agent.

[0051] Embodiment 11: An aerosol generating component as described in any one of embodiments 1 to 10, wherein at least one other aerosol former is selected from the following group: water, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, triacetin, sugar alcohols, terpenes and combinations thereof.

[0052] Embodiment 12: The aerosol-generating component according to any one of Embodiments 1 to 11, wherein the substrate is further impregnated with a fragrance, an active ingredient, or a combination thereof.

[0053] Embodiment 13: The aerosol generating component according to any one of Embodiments 1 to 12, wherein the active ingredient comprises a non-tobacco botanical material, a tobacco component, a nicotine component or a combination thereof.

[0054] Embodiment 14: The aerosol-generating component according to any one of Embodiments 1 to 13, wherein the active ingredient comprises a nicotine component.

[0055] Embodiment 15: An aerosol-generating component as described in any of Embodiments 1 to 14, wherein the substrate is impregnated with two or more aerosol-forming materials at a loading amount of about 15 wt % to about 55 wt % based on the total weight of the impregnated substrate.

[0056] Embodiment 16: An aerosol generating component as described in any one of Embodiments 1 to 15, wherein the substrate is in the form of microparticles, shredded form, film form, paper processed sheet form, cast sheet form, beads form, granules form, rod form or extrudate form.

[0057] Embodiment 17: The aerosol-generating component according to any one of Embodiments 1 to 16, wherein the substrate is formed into a substantially cylindrical shape.

[0058] Embodiment 18: The aerosol-generating component of any one of Embodiments 1 to 17, wherein the substrate comprises tobacco-derived fibers, wood-derived fibers, or a combination thereof.

[0059] Embodiment 19: The aerosol generating component as described in any one of Embodiments 1 to 18, wherein the substrate further comprises one or more binders.

[0060] Embodiment 20: An aerosol generating component as described in any one of embodiments 1 to 19, wherein the one or more binders are selected from alginate / ester, cellulose derivatives, starch, gum, dextran, carrageenan, calcium carbonate or a combination thereof.

[0061] Embodiment 21: An aerosol generating component as described in any of Embodiments 1 to 20, wherein the substrate comprises one or more of the following: calcium carbonate, alginate / ester, one or more cellulose derivatives, starch, wood pulp or tobacco-derived fibers.

[0062] Embodiment 22: An aerosol-generating component as described in any of Embodiments 1 to 21, wherein the two or more aerosol-generating materials are present in a weight ratio of the first aerosol-forming material to the second aerosol-forming material of about 3:1 to about 1:3.

[0063] Embodiment 23: The aerosol-generating component as described in any one of Embodiments 1 to 22, wherein the two or more aerosol-forming materials are glycerol and 1,2-propylene glycol.

[0064] Embodiment 24: An aerosol generating component as described in any of embodiments 1 to 23, wherein the substrate comprises: about 0 weight % to about 5 weight % calcium carbonate; about 1 weight % to about 5 weight % wood pulp; about 70 weight % to about 80 weight % tobacco-derived fibers; and wherein the substrate is impregnated with two or more aerosol-forming materials at a loading amount of about 15 weight % to about 25 weight % based on the total weight of the impregnated substrate.

[0065] Embodiment 25: An aerosol generating component as described in any of embodiments 1 to 24, wherein the substrate comprises: about 45 weight % to about 60 weight % calcium carbonate; about 0 weight % to about 10 weight % alginate / ester; about 0 weight % to about 5 weight % one or more cellulose derivatives; about 0 weight % to about 15 weight % starch; about 0 weight % to about 5 weight % wood pulp; about 0 weight % to about 40 weight % tobacco-derived fibers; and wherein the substrate is impregnated with two or more aerosol-forming materials at a loading amount of about 15 weight % to about 25 weight % based on the total weight of the impregnated substrate.

[0066] Embodiment 26: An aerosol generating component as described in any of embodiments 1 to 25, wherein the substrate comprises: about 40 weight % to about 60 weight % calcium carbonate; about 0 weight % to about 10 weight % alginate / ester; about 0 weight % to about 5 weight % one or more cellulose derivatives; about 0 weight % to about 15 weight % starch; about 0 weight % to about 5 weight % wood pulp; about 0 weight % to about 40 weight % tobacco-derived fibers; and wherein the substrate is impregnated with two or more aerosol-forming materials at a loading amount of about 15 weight % to about 25 weight % based on the total weight of the impregnated substrate.

[0067] Embodiment 27: An aerosol generating component as described in any of embodiments 1 to 26, wherein the substrate comprises: about 5 weight % to about 15 weight % calcium carbonate; about 1 weight % to about 5 weight % one or more cellulose derivatives; about 20 weight % to about 40 weight % starch; about 20 weight % to about 40 weight % tobacco-derived fibers; and wherein the substrate is impregnated with two or more aerosol-forming materials at a loading amount of about 15 weight % to about 25 weight %, based on the total weight of the impregnated substrate.

[0068] Embodiment 28: An aerosol generating component comprising a substrate, wherein the substrate is impregnated with two or more aerosol-forming materials, and the two or more aerosol-forming materials impregnated include: a first aerosol-forming material selected from the following group: glycerol, 1,2-propylene glycol, 1,3-propylene glycol, diethylene glycol, triethylene glycol, polyethylene glycol, triacetin and combinations thereof; and a second aerosol-forming material, which is different from the first aerosol-forming material and selected from the following group: polysorbates, sorbitan esters, fatty acids, fatty acid esters, 1,3-propylene glycol, triethylene glycol, polyethylene glycol, triacetin, waxes, terpenes and sugar alcohols; wherein the first aerosol-forming material and the second aerosol-forming material each have a different boiling point, a different vapor pressure, or a different boiling point and a different vapor pressure; and wherein, based on the total weight of the impregnated substrate, the substrate is impregnated with the two or more aerosol-forming materials at a loading amount of about 5 weight % to about 60 weight %.

[0069] Embodiment 29: An aerosol-generating component as described in Embodiment 28, wherein the substrate is impregnated with two or more aerosol-forming materials at a loading amount of about 15 weight percent to about 30 weight percent based on the total weight of the impregnated substrate.

[0070] Embodiment 30: An aerosol-generating component as described in embodiment 28 or 29, wherein the weight ratio of the first aerosol-forming material to the second aerosol-forming material is about 100:1 to about 1:100.

[0071] Embodiment 31: An aerosol-generating component as described in any one of Embodiments 28 to 3, wherein the weight ratio of the first aerosol-forming material to the second aerosol-forming material is about 3:1 to about 1:3.

[0072] Embodiment 32: An aerosol generating component as described in any one of embodiments 28 to 4, wherein the second aerosol-forming material is selected from the following group: palmitic acid, polyethylene glycol 400, sorbitan tristearate, polysorbate 80 and a combination thereof.

[0073] Embodiment 33: The aerosol-generating component as described in any one of Embodiments 28 to 31, wherein the first aerosol-forming material is glycerol, and the second aerosol-forming material is 1,3-propylene glycol, triethylene glycol, palmitic acid or triacetin.

[0074] Embodiment 34: The aerosol-generating component as described in any one of Embodiments 28 to 31, wherein the first aerosol-forming material is glycerin and the second aerosol-forming material is palmitic acid.

[0075] Embodiment 35: An aerosol generating component as described in any one of embodiments 28 to 31, wherein: the first aerosol forming material is 1,3-propylene glycol, triethylene glycol, 1,2-propylene glycol, or triacetin; and the second aerosol forming material is palmitic acid, polyethylene glycol 400, sorbitan tristearate or polysorbate 80.

[0076] Embodiment 36: An aerosol generating component as described in any one of embodiments 28 to 31, wherein the substrate is impregnated with glycerol, palmitic acid and a third aerosol-forming material selected from the following group: 1,3-propylene glycol, triethylene glycol, 1,2-propylene glycol, triacetin, polyethylene glycol 400, sorbitan tristearate and polysorbate 80.

[0077] Embodiment 37: An aerosol generating component as described in any one of embodiments 28 to 31, wherein the substrate is impregnated with a mixture selected from the following groups: glycerol and palmitic acid; glycerol and 1,3-propylene glycol; glycerol and triethylene glycol; glycerol and triacetin; 1,3-propylene glycol and palmitic acid; 1,3-propylene glycol and polyethylene glycol; 1,3-propylene glycol and polysorbate 80; triethylene glycol and palmitic acid; triethylene glycol and polyethylene glycol; triethylene glycol and polysorbate 80; triacetin and palmitic acid; triacetin and polyethylene glycol; triacetin and polysorbate 80; 1,2-propylene glycol, and palmitic acid; 1,2-propylene glycol, and polyethylene glycol; and 1,2-propylene glycol, and polysorbate 80.

[0078] Embodiment 38: An aerosol-generating component as described in Embodiment 37, wherein the ratio of aerosol-forming materials in each listed mixture is about 3:1 to about 1:3.

[0079] Embodiment 39: An aerosol-generating component as described in any one of Embodiments 28 to 31, wherein the substrate is impregnated with a mixture comprising: glycerol, palmitic acid and 1,2-propylene glycol.

[0080] Embodiment 40: The aerosol generating component as described in embodiment 39, which also includes triacetin.

[0081] Embodiment 41: The aerosol-generating component of any one of Embodiments 28 to 40, wherein the substrate further comprises up to about 10% by weight of water based on the total dry weight of the impregnated substrate.

[0082] Embodiment 42: An aerosol generating component as described in any of Embodiments 28 to 41, wherein the substrate comprises tobacco-derived fibers, wood-derived fibers, plant fibers or plant-derived fibers, synthetic fibers, or a combination thereof; and one or more binders.

[0083] Embodiment 43: An aerosol generating component as described in embodiment 42, wherein the one or more binders are selected from alginate / ester, cellulose derivatives, starch, gum, dextran, carrageenan, calcium carbonate or a combination thereof.

[0084] Embodiment 44: An aerosol generating component as described in any of Embodiments 28 to 43, wherein the substrate comprises: about 40 weight % to about 70 weight % tobacco-derived fibers; about 10 weight % to about 15 weight % cellulose derivatives; and about 5 weight % to about 10 weight % wood pulp.

[0085] Embodiment 45: The aerosol-generating component of any one of Embodiments 28 to 44, wherein the substrate is further impregnated with a flavor, an active ingredient, or a combination thereof.

[0086] Embodiment 46: The aerosol generating component of embodiment 45, wherein the active ingredient comprises a tobacco component, a non-tobacco botanical material, a nicotine component or a combination thereof.

[0087] Embodiment 47: The aerosol-generating component of embodiment 45, wherein the active ingredient comprises a nicotine component.

[0088] Embodiment 48: An aerosol generating component as described in any one of Embodiments 28 to 47, wherein the substrate is in the form of microparticles, shredded form, film form, paper processed sheet form, cast sheet form, beads form, granules form, rod form or extrudate form.

[0089] Embodiment 49: An aerosol generating component as described in any one of Embodiments 28 to 48, wherein the substrate is formed into a substantially cylindrical shape.

[0090] Embodiment 50: An aerosol delivery device comprising: an aerosol generating component as described in any one of embodiments 1 to 49; a heat source configured to heat an impregnated substrate to form an aerosol; and an aerosol path extending from the aerosol generating component to a mouthpiece end of the aerosol delivery device.

[0091] Embodiment 51: An aerosol delivery device as described in Embodiment 50, wherein the heat source includes an electrically powered heating element or a combustible ignition source.

[0092] Embodiment 52: An aerosol delivery device as described in Embodiment 50 or 51, wherein the heat source is a combustible ignition source comprising a carbon-based material.

[0093] Embodiment 53: An aerosol delivery device as described in embodiment 50 or 51, wherein the heat source is an electrically powered heating element.

[0094] Embodiment 54: An aerosol delivery device as described in Embodiment 53, further comprising a power source electrically connected to the heating element.

[0095] Embodiment 55: The aerosol delivery device of Embodiment 54, further comprising a controller configured to control power delivered by the power source to the heating element.

[0096] These and other features, aspects and advantages of the invention will become apparent by reading the following detailed description in conjunction with the accompanying drawings briefly described below. The invention includes any combination of two, three, four or more of the above-described embodiments and any combination of two, three, four or more features or elements set forth in this disclosure, whether or not these features or elements are explicitly combined with these terms in the description of the specific embodiments herein. This disclosure is intended to be read as a whole, so that any separable features or elements of the disclosed invention, in any of its various aspects and embodiments, should be deemed to be intended to be combinable unless the context clearly dictates otherwise.

[0097] BRIEF DESCRIPTION OF THE DRAWINGS

[0098] The above generally describes the aspects of the present disclosure, which will be described below in conjunction with the accompanying drawings, which are not necessarily drawn to scale. The drawings are only exemplary and should not be understood to limit the present disclosure.

[0099] Figure 1shows a perspective view of an aerosol delivery device including a control body and an aerosol generating component according to an exemplary embodiment of the present disclosure, wherein the generating component and the control body are coupled to each other;

[0100] Figure 2 The exemplary embodiment according to the present disclosure is shown Figure 1 A perspective view of an aerosol delivery device of , wherein the aerosol generating component and the control body are decoupled from each other;

[0101] Figure 3 shows a perspective schematic diagram of an aerosol generating component according to an exemplary embodiment of the present disclosure;

[0102] Figure 4 shows a perspective cross-sectional view of a substrate portion of an aerosol generating component according to an exemplary embodiment of the present disclosure;

[0103] Figure 5 shows a perspective view of an aerosol generating component according to an exemplary embodiment of the present disclosure;

[0104] Figure 6 The outer wrapper is shown removed according to an exemplary embodiment of the present disclosure. Figure 5 A perspective view of an aerosol generating component;

[0105] Figure 7 is a bar graph depicting the heat energy required for vaporization of glycerol, 1,2-propylene glycol, and mixtures thereof as measured by differential scanning calorimetry (DSC);

[0106] Figure 8 is a graphical representation of superimposed ion current curves of glycerol in paper treated reconstituted samples with different glycerol-1,2-propanediol loadings; and

[0107] Fig. 9 is a graphic representation of superimposed ion current curves of glycerol in beaded tobacco samples with different glycerol-1,2-propylene glycol loadings;

[0108] Fig.10 is a graphical representation of superimposed thermogravimetric analysis thermograms of a mixture of aerosol-forming materials; and

[0109] Fig.11 is a graphic representation of superimposed thermogravimetric analysis thermograms of a handsheet substrate impregnated with a mixture of aerosol-forming materials. DETAILED DESCRIPTION

[0110] The present disclosure will be described more fully below with reference to exemplary embodiments thereof. These exemplary embodiments are described so that the present disclosure will be complete and perfect and fully demonstrate the scope of the present disclosure to those skilled in the art. In fact, the present disclosure can be implemented in many different forms and should not be construed as limited to the embodiments described herein; and, these embodiments are provided so that the present disclosure can satisfy legal requirements.

[0111] As used in the specification and claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0112] The term "about" used throughout this specification is used to describe and explain small fluctuations. For example, the term "about" can refer to less than or equal to ±10%, such as less than or equal to ±5%, less than or equal to ±2%, less than or equal to ±1%, less than or equal to ±0.5%, less than or equal to ±0.2%, less than or equal to ±0.1%, or less than or equal to ±0.05%. Whether or not explicitly stated, all numerical values ​​are modified by the term "about". Numerical values ​​modified by the term "about" include specific values. For example, "about 5.0" must include 5.0.

[0113] Reference to "dry weight percentage" or "dry weight basis" refers to the weight based on dry ingredients (ie, all ingredients except water). Unless otherwise indicated, all weight percentage values ​​herein are dry weight percentages.

[0114] As described below, exemplary embodiments of the present disclosure relate to an aerosol-generating component including a substrate, wherein the substrate contains two or more aerosol-forming materials, wherein the two or more aerosol-forming materials are impregnated with: a first aerosol-forming material and a second aerosol-forming material, wherein the first aerosol-forming material and the second aerosol-forming material each have a different boiling point and / or a different vapor pressure. Other exemplary embodiments of the present disclosure relate to an aerosol delivery device, comprising: an aerosol-generating component as disclosed herein; a heat source configured to heat the aerosol-forming material impregnated in the substrate to form an aerosol; and an aerosol path extending from the aerosol-generating component to the mouthpiece end of the aerosol delivery device.

[0115] Aerosol generating components and aerosol delivery devices

[0116] Some embodiments of the aerosol generating components according to the present disclosure use electrical energy to heat the material to form an inhalable substance (e.g., electrically heating the tobacco product). In other embodiments of the aerosol generating components according to the present disclosure, a ignitable heat source is used to heat the material (preferably without burning the material to any significant degree) to form an inhalable substance (e.g., carbon heating the tobacco product). Preferably, the material is heated without burning the material to any significant degree. The components of this system have a form of product that is compact enough to be considered as a handheld device. That is, in the sense that the aerosol is mainly derived from the byproducts of the combustion or pyrolysis of tobacco, the use of the components of the preferred aerosol delivery system does not result in the generation of smoke, but the use of those preferred systems will produce vapors caused by the volatilization or evaporation of certain components contained therein. In some exemplary embodiments, the components of the aerosol delivery device can be characterized as electronic cigarettes, and those electronic cigarettes most preferably contain tobacco and / or components derived from tobacco, and thus deliver tobacco-derived components in the form of aerosols.

[0117] The aerosol generating components of a preferred aerosol delivery device can provide many of the sensations of smoking a cigarette, cigar, or pipe (e.g., inhalation and exhalation habits, types of taste or flavor, sensory effects, physical sensations, usage habits, visual cues, such as those provided by visible aerosols, etc.), without any substantial degree of combustion of any of its components. For example, a user of an aerosol delivery device according to some exemplary embodiments of the present disclosure can hold and use the component more like a smoker using a traditional type of smoking article, taking puffs or inhalations at one end of the device at selected time intervals to inhale the aerosol generated by the device.

[0118] Although the system is generally described herein in terms of embodiments associated with an aerosol delivery device and / or an aerosol generating component (such as a so-called "electronic cigarette" or "tobacco heating product"), it should be understood that the mechanisms, components, features, and methods can be implemented in many different forms and associated with a variety of articles. For example, the description provided herein can be used in conjunction with embodiments of traditional smoking articles (e.g., cigarettes, cigars, pipes, etc.), heat-not-burn cigarettes, and related packaging of any product disclosed herein. Therefore, it should be understood that the descriptions of the mechanisms, components, features, and methods disclosed herein are discussed in embodiments associated with an aerosol delivery device by way of example only, and these descriptions can be implemented and used in a variety of other products and methods.

[0119] The aerosol delivery device and / or aerosol generating component of the present disclosure can also be characterized as a product or drug delivery product that produces steam. Therefore, the product or device can be adjusted to provide one or more substances (for example, fragrances and / or active pharmaceutical ingredients) in an inhalable form or state. For example, the inhalable substance can be substantially in the form of steam (that is, a substance in the gas phase at a temperature below its critical point). Alternatively, the inhalable substance can be in the form of an aerosol (that is, a suspension of fine solid particles or droplets in a gas). For the purpose of simplification, the term "aerosol" used herein means steam, gas and aerosol in a form or type suitable for human inhalation, whether visible or not, and whether it can be considered as a smoke-like form. The physical form of the inhalable substance is not necessarily limited by the properties of the device of the present invention, but can depend on the properties of the medium and whether the inhalable substance itself exists in a vapor state or an aerosol state. In some embodiments, the terms "steam" and "aerosol" can be interchangeable. Therefore, for simplicity, unless otherwise stated, the terms "steam" and "aerosol" used to describe various aspects of the present invention should be understood to be interchangeable.

[0120] In some embodiments, the aerosol delivery device of the present disclosure may include some combination of the following components: a power source (e.g., an electrical power source), at least one control component (e.g., a device for driving, controlling, adjusting, and stopping the current used to generate heat by controlling the current from the power source to other components of the article - for example, a microprocessor used alone or as part of a microcontroller), a heat source (e.g., a resistive heating element or other component and / or an induction coil or other related component and / or one or more radiant heating elements), and an aerosol generating component, wherein the aerosol generating component includes a substrate portion that is capable of generating an aerosol after sufficient heat is applied. Note that one or more of the above components can be physically combined. For example, in some embodiments, a conductive heater trace can be printed on the surface of a substrate material described herein (e.g., a nanocellulose substrate film) using a conductive ink so that the heater trace can be powered by the power source and used as a resistive heating element. Exemplary conductive inks include graphene inks and inks containing various metals, such as inks containing silver, gold, palladium, platinum, and alloys thereof, or combinations thereof (e.g., silver-palladium or silver-platinum inks), which can be printed onto a surface using a variety of processes, such as gravure printing, flexographic printing, offset printing, screen printing, inkjet printing, or other suitable printing methods.

[0121] In different embodiments, many of these components may be provided in an outer body or housing, which in some embodiments may be referred to as a shell. The overall design of the outer body or housing may vary, and the form or configuration of the outer body may vary, which may define the overall size and shape of the aerosol delivery device. Although other configurations are possible, in some embodiments an elongated body similar in shape to a cigarette or cigar may be formed by a single integral shell, or the elongated shell may be formed by two or more separable bodies. For example, an aerosol delivery device may include an elongated shell or body, which may be substantially tubular in shape and, therefore, similar in shape to a conventional cigarette or cigar. In one example, all of the components of the aerosol delivery device are contained in one shell or body. In other embodiments, the aerosol delivery device may include two or more shells that are connected and separable. For example, an aerosol delivery device may have a control body at one end that includes a housing containing one or more reusable components (e.g., a storage battery (such as a rechargeable battery and / or a rechargeable supercapacitor) and various electronic devices for controlling the operation of the article) and a removable outer body or housing containing a disposable portion (e.g., a disposable flavor-containing aerosol generating component) at the other end.

[0122] In other embodiments, the aerosol generating component of the present disclosure may generally include an ignitable heat source configured to heat the substrate material. The substrate material and / or at least part of the heat source may be covered by an outer wrap or wrapping material, a casing, a component, a module, a member, etc. The overall design of the enclosure is variable, and the form or configuration of the enclosure is also variable, and the enclosure defines the overall size and shape of the aerosol generating component. Although other configurations are feasible, in some aspects, it may be desirable that the overall design, size, and / or shape of these embodiments are similar to the overall design, size, and / or shape of a traditional cigarette or cigar. In various aspects, the heat source may be able to generate heat to aerosolize the substrate material, the substrate material including: for example, a substrate material related to an aerosol-forming material, an extruded structure, and / or a substrate, tobacco and / or tobacco-related materials, such as materials naturally present in tobacco, which are directly separated from tobacco or synthetically prepared in solid or liquid form (e.g., beads, sheets, silk, wrappers), etc.

[0123] Based on the further disclosure provided below, more specific formats, configurations, and arrangements of various substrate materials, aerosol generating components, and components within the disclosed aerosol delivery devices will be apparent. Additionally, the selection of various aerosol delivery device components may be understood after considering commercially available electronic aerosol delivery devices. Additionally, the arrangement of components in the aerosol delivery device may also be understood after considering commercially available electronic aerosol delivery devices.

[0124] In this regard, Figure 1 An aerosol delivery device 100 according to an exemplary embodiment of the present disclosure is shown. The aerosol delivery device 100 may include a control body 102 and an aerosol generating component 104. In various embodiments, the aerosol generating component 104 and the control body 102 may be permanently or removably aligned in a functional relationship. In this regard, Figure 1 The aerosol delivery device 100 is shown in a coupled configuration, and Figure 2 The aerosol delivery device 100 is shown in a decoupled configuration. Various mechanisms can connect the aerosol generating component 104 to the control body 102 to produce a threaded engagement, a press fit engagement, an interference fit, a slide fit, a magnetic engagement, and the like.

[0125] In various embodiments, the aerosol delivery device 100 according to the present disclosure may have various overall shapes, including but not limited to an overall shape that may be defined as a generally rod-shaped or generally tubular or generally cylindrical shape. Figure 1 to Figure 2 In some embodiments, the device 100 has a substantially circular cross-section; however, the present disclosure also includes other cross-sectional shapes (e.g., elliptical, square, triangular, etc.). For example, in some embodiments, one or both of the control body 102 and the aerosol generating component 104 (and / or any subcomponents) may have a substantially rectangular shape, such as a substantially rectangular cube shape (similar to a USB flash drive). In other embodiments, one or both of the control body 102 or the aerosol generating component 104 (and / or any subcomponents) may have other handheld shapes. For example, in some embodiments, the control body 102 may have a small box shape, various pod mod shapes, or a keychain shape. Therefore, this language describing the physical shape of the article may also be applied to its individual components, including the control body 102 and the aerosol generating component 104.

[0126] In various embodiments, the alignment of the components in the aerosol delivery device of the present disclosure can vary. In some embodiments, the substrate portion can be located near the heat source part, so that the aerosol delivered to the user is as much as possible. However, other structures are not excluded. Usually, the heat source can be located close enough to the substrate portion, so that the heat from the heat source can volatilize the substrate portion (and one or more spices (flavorant), medicine, etc. that can be delivered to the user in a similar manner in some embodiments), and form an aerosol to deliver to the user. When the heat source heats the substrate portion, the aerosol is formed, released or generated in a physical form suitable for the consumer to inhale. It should be noted that the above-mentioned terms are meant to be interchangeable, so that mentioning release, releasing, releasing or being released includes forming or generating, forming or generating, forming or generating, forming or generating and being formed or generating. Specifically, inhalable material is released in the form of vapor or aerosol or its mixture, wherein, unless otherwise noted, these terms can be used interchangeably in this article.

[0127] As noted above, the aerosol delivery device 100 of various embodiments may include batteries and / or other ionized power sources to provide current sufficient to provide various functions for the aerosol delivery device, for example, power supply of a heat source, power supply of a control system, power supply of an indicator, etc. As will be discussed in more detail below, the power supply may be in various embodiments. Preferably, the power supply is capable of delivering enough power to quickly activate the heat source, thereby providing the formation of an aerosol, and providing power to the article by using it for a desired duration. In some embodiments, the size of the power supply is suitable for being conveniently assembled in the aerosol delivery device so that the aerosol delivery device can be easily operated. Examples of available power sources include lithium-ion batteries, which are preferably rechargeable (e.g., rechargeable lithium-manganese dioxide batteries). Specifically, lithium polymer batteries can be used because such batteries can provide higher safety. Other types of batteries may also be used - for example, N50-AAA CADNICA nickel-chromium button batteries. In addition, the preferred power supply has a sufficiently light weight without reducing the desired smoking experience. Some examples of useful voltages are described in U.S. Patent No. 9,484,155 to Peckerar et al. and U.S. Patent Application Publication No. 2017 / 0112191 to Sur et al., filed on October 21, 2015; the disclosures of each of these documents are incorporated herein by reference in their respective entireties.

[0128] In a specific embodiment, one or both of the control body 102 and the aerosol generating component 104 can be disposable or reusable. For example, the control body 102 can have a replaceable battery or a rechargeable battery, a solid-state battery, a thin-film solid-state battery, a rechargeable supercapacitor, etc., and can therefore be combined with any type of recharging technology, including connection to a typical wall socket; connection to a car charger (e.g., a cigarette lighter socket); connection to a computer, such as through a universal serial bus (USB) cable or connector (e.g., USB 2.0, 3.0, 3.1, USB Type C (USB Type-C)); connection to a photovoltaic cell (sometimes called a solar cell) or a solar panel of a solar cell; no charger is required, for example, a charger using inductive wireless charging (e.g., wireless charging including the Qi wireless charging standard from the Wireless Power Consortium (WPC)), or a wireless radio frequency (RF)-based charger. Examples of inductive wireless charging systems are described in U.S. Patent Application Publication No. 2017 / 0112196 to Sur et al., which is incorporated herein by reference in its entirety. Additionally, in some embodiments, the aerosol generating component 104 can include a disposable device. Disposable components for use with control bodies are described in US Pat. No. 8,910,639 to Chang et al., which is incorporated herein by reference in its entirety.

[0129] In other embodiments, the power source may also include a capacitor. The discharge of the capacitor may be faster than a battery, and may be charged between puffs, allowing the battery to be discharged into the capacitor at a lower rate than directly using it to power a heat source. For example, a supercapacitor-e.g., an electric double layer capacitor (EDLC)-may be used separately from a battery or in combination with a battery. When used alone, the supercapacitor may be charged before each use of the article. Therefore, the device may also include a charger component that may be attached to the smoking article between uses to fill up the supercapacitor.

[0130] Other components can be used in the aerosol delivery device of the present disclosure. For example, the aerosol delivery device can include a flow sensor that is sensitive to changes in air flow (i.e., suction-driven heating) or pressure changes when a consumer draws on the product. Other available existing drive / deactivation mechanisms can include a temperature-driven on / off switch or a lip pressure-driven switch. An exemplary mechanism that can provide this suction-actuated capability includes a 163PC01D36 silicon sensor, which is manufactured by the MicroSwitch division of Honeywell, Inc., Freeport, Ill, of Freeport, Illinois. Representative flow sensors, current regulation components, and other current control components (including microcontrollers, sensors, and switches for aerosol delivery devices) are described in U.S. Pat. No. 4,735,217 to Gerth et al., U.S. Pat. No. 4,922,901 to Brooks et al., U.S. Pat. No. 4,947,874 to McCafferty et al., U.S. Pat. No. 5,372,148 to Fleischhauer et al., U.S. Pat. No. 6,040,560 to Fleischhauer et al., U.S. Pat. No. 7,040,314 to Nguyen et al., and U.S. Pat. No. 8,205,622 to Pan, which are incorporated herein by reference in their entirety. Reference is also made to the control scheme described in U.S. Pat. No. 9,423,152 to Ampolini et al., the entire contents of which are incorporated herein by reference in their entirety.

[0131] In another example, an aerosol delivery device may include: a first conductive surface configured to contact a first body part of a user holding the device; and a second conductive surface electrically isolated from the first conductive surface and configured to contact a second body part of the user. Thus, when the aerosol delivery device detects a change in conductivity between the first conductive surface and the second conductive surface, the vaporizer is activated to vaporize the substance so that the vapor can be inhaled by the user holding the unit. The first body part and the second body part can be a portion of a lip or a hand. The two conductive surfaces can also be used to charge a battery contained in a personal vaporizer unit. The two conductive surfaces can also form or be part of a connector that can be used to output data stored in a memory. Reference is made to U.S. Patent No. 9,861,773 to Terry et al., which is incorporated herein by reference in its entirety.

[0132] In addition, U.S. Patent No. 5,154,192 to Sprinkel et al. discloses an indicator for a smoking article; U.S. Patent No. 5,261,424 to Sprinkel, Jr. discloses a piezoelectric sensor associated with the mouth end of the device to detect user lip movement associated with taking a puff and then trigger heating of the heating device; U.S. Patent No. 5,372,148 to McCafferty et al. discloses a puff sensor for controlling the flow of energy into a heating load array in response to a pressure drop across a mouthpiece; U.S. Patent No. 5,967,148 to Harris et al. discloses a container in a smoking device, which includes: an identifier for detecting infrared transmittance non-uniformity of an inserted component and a controller for executing a detection program when the component is inserted into the container; U.S. Patent No. 6,040,560 to Fleischhauer et al. describes a device having multiple A defined executable power cycle of a differential phase; U.S. Patent No. 5,934,289 to Watkins et al. discloses a photonic-photoelectric component; U.S. Patent No. 5,954,979 to Counts et al. discloses a device for varying the resistance to draw through a smoking device; U.S. Patent No. 6,803,545 to Blake et al. discloses a specific battery construction for a smoking device; U.S. Patent No. 7,293,565 to Griffen et al. discloses various charging systems for use with a smoking device; U.S. Patent No. 8,402,976 to Fernando et al. discloses a computer interface device for a smoking device to facilitate charging and allow a computer to control the device; U.S. Patent No. 8,689,804 to Fernando et al. discloses an identification system for a smoking device; and PCT Patent Application Publication No. WO 2010 / 003480 to Flick discloses a fluid flow sensing system that indicates draws in an aerosol generating system; all of the above disclosures are incorporated herein by reference in their entirety.

[0133] Other examples of components associated with electronic aerosol delivery articles and disclosed materials or components that may be used in the present device include: U.S. Pat. No. 4,735,217 to Gerth et al.; U.S. Pat. No. 5,249,586 to Morgan et al.; U.S. Pat. No. 5,666,977 to Higgins et al.; U.S. Pat. No. 6,053,176 to Adams et al.; U.S. Pat. No. 6,164,287 to White; U.S. Pat. No. 6,196,218 to Voges; U.S. Pat. No. 6,810,883 to Felter et al.; U.S. Pat. No. 6,854,461 to Nichols; U.S. Pat. No. 7,832,410 to Hon; U.S. Pat. No. 7,513,253 to Kobayashi; U.S. Pat. No. 7,89 No. 6,006 to Shayan; No. 6,772,756 to Shayan; Nos. 8,156,944 and 8,375,957 to Hon; No. 8,794,231 to Thorens et al.; No. 8,851,083 to Oglesby et al.; Nos. 8,915,254 and 8,925,555 to Monsees et al.; No. 9,220,302 to DePiano et al.; U.S. Patent Application Publication Nos. 2006 / 0196518 and 2009 / 0188490 to Hon; U.S. Patent Application Publication No. 2010 / 0024834 to Oglesby et al.; U.S. Patent Application Publication No. 2010 / 0307518 to Wang; PCT Patent Application Publication No. WO 2006 / 0196518 to Hon; 2010 / 091593; and PCT Patent Application Publication No. WO 2013 / 089551 to Foo, each of which is incorporated herein by reference in its entirety. In addition, U.S. Patent Application Publication No. 2017 / 0099877 to Worm et al., filed on October 13, 2015, discloses capsules that can be included in aerosol delivery devices and pouch-shaped configurations for aerosol delivery devices, which is incorporated herein by reference in its entirety. In various embodiments, various materials disclosed in the aforementioned documents can be incorporated into the present device, and all of the aforementioned disclosures are incorporated herein by reference in their entirety.

[0134] See also Figure 2, the aerosol generating component 104 includes: a heating end 106, which is configured to be inserted into the control body 102; and a mouth end 108, on which the user draws to generate an aerosol. At least a portion of the heating end 106 may include a substrate portion 110. As will be discussed in more detail below, in various embodiments, the substrate portion 110 may include various materials impregnated with an aerosol-forming material. In various embodiments, the aerosol generating component 104 or a portion thereof may be wrapped with an exterior overwrap material 112. In various embodiments, the mouth end 108 of the aerosol generating component 104 includes a filter 114, for example, the filter may be made of cellulose acetate or polypropylene material. The filter 114 may additionally or alternatively include a strand of tobacco material, for example, as described in U.S. Pat. No. 5,025,814 to Raker et al., which is incorporated herein by reference in its entirety. In various embodiments, the filter 114 can improve the structural integrity of the mouth end of the aerosol source component, and / or provide filtering capabilities (if necessary), and / or provide suction resistance. In some embodiments, the filter can include discrete sections. For example, some embodiments may include a section that provides filtering, a section that provides suction resistance, a hollow section that provides cooling space for the aerosol, a section that provides increased structural integrity, other filter sections, and any one or any combination of the above.

[0135] In some embodiments, the outer packaging material may include a material that resists heat transfer, which may include paper or other fiber materials, such as cellulose materials. The outer packaging material may also include at least one filler material embedded or dispersed in the fiber material. In various embodiments, the filler material may have water-soluble particles. In addition, the filler material may include inorganic components. In various embodiments, the outer packaging may be formed by multiple layers, such as, a lower loose layer and a cover layer (such as, a typical wrapping paper in a cigarette). Such materials may include, for example, lightweight "coarse fibers", such as flax, hemp, sisal, straw and / or thatch (esparto). The outer outer packaging may also include materials (such as cellulose acetate) that are commonly used for filter elements of traditional cigarettes. Further, the excess length of the outer outer packaging at the mouth end 108 of the aerosol generating component may be used to simply separate the substrate portion from the consumer's mouth, or provide a space for placing a filter material as described below, or affect the suction on the product or affect the flow characteristics of the steam or aerosol that leaves the device during the suction. Further discussion related to the construction of outer overpack materials that can be used with the present disclosure can be found in US Pat. No. 9,078,473 to Worm et al., which is incorporated herein by reference in its entirety.

[0136] In various embodiments, other components may be present between the substrate portion 110 and the mouth end 108 of the aerosol generating component 104. For example, in some embodiments, one or any combination of the following may be positioned between the substrate portion 110 and the mouth end 108 of the aerosol generating component 104: an air gap; a hollow tube structure; a phase change material for cooling the air; a flavor release medium; ion exchange fibers with selective chemical adsorption capabilities; aerosol particles as a filter medium; and other suitable materials. Some examples of possible phase change materials include, but are not limited to, salts such as AgNO 3 、AlCl 3 、TaCl 3 、InCl 3 SnCl 2 , A1 3 and TiI 4 ; Metals and metal alloys such as selenium, tin, indium, tin-zinc, indium-zinc or indium-bismuth; and organic compounds such as D-mannitol, succinic acid, p-nitrobenzoic acid, hydroquinone and adipic acid. Other examples are described in U.S. Pat. No. 8,430,106 to Potter et al., the entire contents of which are incorporated herein by reference.

[0137] As will be discussed in more detail below, the aerosol generating components disclosed herein are configured to be used with a conductive and / or inductive heat source, thereby heating the substrate material to form an aerosol. In various embodiments, the conductive heat source may include a heating assembly, which includes a resistive heating member. The resistive heating member may be configured to generate heat when directing an electric current through. The conductive material that can be used as the resistive heating member may be those that have low mass, low density and moderate resistivity and are thermally stable at the temperature experienced during use. The available heating member heats and cools quickly, and thus provides efficient use of energy. The rapid heating of the member may be advantageous for almost immediate volatilization of the aerosol-forming material in its vicinity. Rapid cooling prevents a large amount of volatilization (and therefore waste) of the aerosol-forming material during the period when the aerosol is not required to be formed. The heating member can also allow relatively accurate control of the temperature range experienced by the aerosol-forming material, especially when time-based current control is adopted. The available conductive material preferably does not chemically react with the heated material (e.g., aerosol-forming material and other inhalable material materials), so as not to adversely affect the flavor or content of the generated aerosol or vapor. Some exemplary non-limiting materials that can be used as conductive materials include carbon, graphite, carbon / graphite composites, metals, ceramics such as metal and non-metal carbides, nitrides, oxides, silicides, intermetallic compounds, cermets, metal alloys and metal foils. In particular, refractory materials can be used. Various materials can be mixed to obtain the desired resistivity, mass and thermal conductivity properties. In a particular embodiment, metals that can be used include, for example, nickel, chromium, alloys of nickel and chromium (e.g., nichrome) and steel. Materials that can be used to provide resistive heating are described in the following references: U.S. Patent No. 5,060,671 to Counts et al.; U.S. Patent No. 5,093,894 to Deevi et al.; U.S. Patent No. 5,224,498 to Deevi et al.; U.S. Patent No. 5,228,460 to Sprinkel, Jr. et al.; U.S. Patent No. 5,322,075 to Deevi et al.; U.S. Patent No. 5,353,813 to Deevi et al.; U.S. Patent No. 5,468,936 to Deevi et al. ; U.S. Patent No. 5,498,850 to Das; U.S. Patent No. 5,659,656 to Das; U.S. Patent No. 5,498,855 to Deevi et al.; U.S. Patent No. 5,530,225 to Hajaligol; U.S. Patent No. 5,665,262 to Hajaligol; U.S. Patent No. 5,573,692 to Das et al.; and U.S. Patent No. 5,591,368 to Fleischhauer et al., the disclosures of which are incorporated herein by reference in their entirety.

[0138] In various embodiments, various forms of heating components can be provided, for example, foil form, foam form, grid form, hollow sphere form, hemisphere form, disc form, spiral form, fiber form, wire form, film form, yarn form, strip form, ribbon form or cylinder form. The heating component generally comprises a metal material and is configured to generate heat due to resistance associated with the passage of current therethrough. The resistive heating component can be located close to and / or in direct contact with a substrate portion. For example, in some embodiments, the processing heat component can include a cylinder or other heating device located in the control body 102, wherein the cylinder is composed of one or more conductive materials, including but not limited to copper, aluminum, titanium, gold, silver, iron, steel, brass, bronze, carbon (e.g., graphite) or any combination thereof. In various embodiments, the heating construction can also be coated with any of these conductive materials or other conductive materials. The heating member can be located near the engagement end of the control body 102 and can be configured to substantially surround a portion of the heating end 106 of the aerosol source member 104, wherein the aerosol generating component 104 includes a substrate portion 110. In this manner, when the aerosol source member is inserted into the control body 102, the heating member can be located near the substrate portion 110 of the aerosol generating component 104. In other examples, when the aerosol generating component is inserted into the control body, at least a portion of the heating member can penetrate at least a portion of the aerosol generating component (e.g., one or more prongs and / or spikes that penetrate the aerosol generating component). Although in some embodiments, the heating member can include a cylinder, it should be noted that in other embodiments, the heating member can take a variety of forms and in some embodiments can be in direct contact with and / or penetrate the substrate portion.

[0139] As will be discussed in more detail below, in addition to being configured for use with a conductive heat source, the present disclosure can also be configured for use with an inductive heat source to heat a portion of the substrate to form an aerosol. In various embodiments, the inductive heat source can include a resonant transformer, which can include a resonant transmitter and a resonant receiver (e.g., a susceptor). In some embodiments, the resonant transmitter and the resonant receiver can be located in the control body 102. In other embodiments, the resonant receiver or a portion thereof can be located in the aerosol source member 104. For example, in some embodiments, the control body 102 can include a resonant transmitter, for example, the resonant transmitter can include a foil material, a coil, a cylinder, or other structure configured to generate an oscillating magnetic field; and a resonant receiver, which can include one or more prongs extending into or surrounded by a substrate portion. In some embodiments, the aerosol generating component is in close contact with the resonant receiver.

[0140] In other embodiments, the resonant transmitter may include a spiral coil that is configured to define a cavity in which the aerosol generating component, particularly the substrate portion of the aerosol generating component, is received. In some embodiments, the spiral coil may be located between the outer wall of the device and the receiving cavity. In one embodiment, the coil winding may have a circular cross-sectional shape; however, in other embodiments, the coil winding may have a variety of other cross-sectional shapes, including but not limited to elliptical, rectangular, L-shaped, T-shaped, triangular, and combinations thereof. In another embodiment, a pin may extend to a portion of the receiving cavity, wherein the pin may include a resonant transmitter, such as a resonant transmitter including a coil structure around or inside the pin. In various embodiments, the aerosol source component may be housed in the receiving cavity, wherein one or more components of the aerosol source component may be used as a resonant receiver. In some embodiments, the aerosol generating component includes a resonant receiver. Other possible resonant transformer components (including resonant transmitters and resonant receivers) are described in U.S. Patent Application No. 15 / 799,365, entitled "Induction Heating Aerosol Delivery Device," filed on October 31, 2017, which is incorporated herein by reference in its entirety.

[0141] Substrate

[0142] As described above, in various embodiments, the substrate portion 110 may include various substrate materials impregnated with two or more aerosol-forming materials. In some embodiments, the substrate includes tobacco-derived fibers, hemp, wood or wood-derived fibers, or combinations thereof.

[0143] In various embodiments, tobacco-derived fibers can include finely ground tobacco material (milled tobacco material). Available tobacco material in the present disclosure can change, and can include: for example, flue-cured tobacco (flue-cured tobacco), burley tobacco (burley tobacco), oriental tobacco (Oriental tobacco) or Maryland tobacco (Maryland tobacco), dark tobacco (dark tobacco), dark-fired tobacco (dark-fired tobacco) and yellow flower tobacco (Rustica tobacco) and other rare or special tobacco, or their blend. Tobacco material can also include so-called "blending" form and processing form, such as processed tobacco stems (for example, cut-rolled (cut-rolled) or cut-puffed (cut-puffed) stems), volume expansion tobacco (for example, puffed tobacco, such as dry ice puffed tobacco (DIET), preferably cut filler (cut filler) form), and / or reconstructed tobacco (for example, using papermaking type or casting sheet type process to manufacture regenerated tobacco). A variety of representative tobacco types, types of tobacco processing, and types of tobacco blends are described in the following references: U.S. Patent No. 4,836,224 to Lawson et al.; U.S. Patent No. 4,924,888 to Perfetti et al.; U.S. Patent No. 5,056,537 to Brown et al.; U.S. Patent No. 5,159,942 to Brinkley et al.; U.S. Patent No. 5,220,930 to Gentry; U.S. Patent No. 5,360,023 to Blakley et al.; U.S. Patent No. 6,701,936 to Shafer et al.; U.S. Patent No. 7,011,096 to Li et al.; and U.S. Patent No. 7,017,585 to Li et al.; U.S. Patent No. 7,025,066 to Lawson et al.; U.S. Patent Application Publication No. 2004-0255965 to Perfetti et al.; PCT Patent Application Publication No. WO 2004-0255965 to Bereman 02 / 37990;And Bombick et al. Fund.Appl.Toxicol., 39, pp. 11-17 (1997), the document is incorporated herein by reference in its entirety.Operable other tobacco compositions are disclosed in Robinson et al. U.S. Patent No. 7,726,320, the patent document is incorporated herein by reference in its entirety.In some embodiments, finely ground tobacco material (milled tobacco material) can include a blend of flavorful and aromatic tobacco.In another embodiment, the tobacco material may include a reconstituted tobacco material, such as described in Pryor et al. U.S. Patent No. 4,807,809 and Pryor et al. U.S. Patent No. 4,889,143 and Raker U.S. Patent No. 5,025,814, which are incorporated herein by reference in their entirety. In addition, the reconstituted tobacco material may include reconstituted tobacco paper described for cigarette types, which is described in Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco, a monograph by RJ Reynolds Tobacco Company (1988), which is incorporated herein by reference in its entirety.

[0144] In certain embodiments, the substrate includes a reconstituted tobacco material, for example, those using various casting / casting and papermaking techniques known in the art. The reconstituted tobacco material may include wood pulp, tobacco fiber, botanical or other cellulose components. In some embodiments, the addition of nanocellulose material to the reconstituted tobacco material can be used to enhance the absorbency and mechanical strength of the resulting material. Reconstituted tobacco materials and methods for providing the materials are described in U.S. Pat. No. 4,674,519 to Keritsis et al.; U.S. Pat. No. 4,807,809 to Pryor et al.; U.S. Pat. No. 4,889,143 to Pryor et al.; U.S. Pat. No. 4,941,484 to Clapp et al.; U.S. Pat. No. 4,972,854 to Kiernan et al.; U.S. Pat. No. 4,987,906 to Young et al.; U.S. Pat. No. 5,025,814 to Raker; U.S. Pat. No. 6,674,819 to Young et al. No. 5,099,864 to Sohn et al.; No. 5,143,097 to Sohn et al.; No. 5,159,942 to Brinkley et al.; No. 5,322,076 to Brinkley et al.; No. 5,339,838 to Young et al.; No. 5,377,698 to Litzinger et al.; No. 5,501,237 to Young; No. 6,216,707 to Kumar; each of which is incorporated herein by reference in its entirety.

[0145] In some embodiments, the substrate comprises about 0% to about 80% tobacco-derived fibers, or about 0% to about 40% tobacco-derived fibers, or about 20% to about 40% tobacco-derived fibers, based on a weight basis. In some embodiments, for example, the substrate comprises about 0%, about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, or about 80% tobacco-derived fibers.

[0146] In some embodiments, the substrate can include plant-derived non-tobacco materials, including but not limited to hemp, flax, sisal, straw, Spanish grass and / or cellulose pulp materials. In various other embodiments, the substrate material can include reconstituted tobacco itself or reconstituted tobacco in combination with other fibrous materials. Some exemplary methods and methods for providing reconstituted tobacco sheets (including casting / casting and papermaking techniques) are described in the following documents: U.S. Patent No. 4,674,519 to Keritsis et al.; U.S. Patent No. 4,941,484 to Clapp et al.; U.S. Patent No. 4,987,906 to Young et al.; U.S. Patent No. 4,972,854 to Kiernan et al.; U.S. Patent No. 5,099,864 to Young et al.; U.S. Patent No. 6,099,864 to Sohn et al. No. 5,143,097; No. 5,159,942 of Brinkley et al.; No. 5,322,076 of Brinkley et al.; No. 5,339,838 of Young et al.; No. 5,377,698 of Litzinger et al.; No. 5,501,237 of Young; and No. 6,216,707 of Kumar; each of the documents is incorporated herein by reference in its entirety. In some cases, processed tobacco (e.g., certain types of reconstituted materials) can be used as longitudinally extending strands. See, for example, the construction type is described in Raker's U.S. Patent No. 5,025,814, which is incorporated herein by reference in its entirety. In addition, certain types of reconstituted tobacco sheets can be formed, rolled or gathered into desired structures. In other embodiments, the substrate material can include various types of inorganic fillers (e.g., glass fibers, metal wires / sieves, etc.) and / or (organic) synthetic polymers. In various embodiments, these "fibrous" materials can be unstructured (eg, randomly distributed like the cellulose fibers in a tobacco sheet) or structured (eg, a grid of wires).

[0147] In some embodiments, the substrate comprises from about 0% to about 5% wood fibers or wood-derived fibers, such as about 0%, about 1%, about 2%, about 3%, about 4%, or about 5% wood fibers or wood-derived fibers, on a weight basis.

[0148] In some embodiments, the substrate portion 110 may further include flame retardant materials, conductive fibers or particles for heat conduction / induction, or any combination thereof. An example of a flame retardant material is ammonium phosphate. In some embodiments, other flame retardant / combustion materials and additives may be included in the substrate portion 110, and may include organic phosphorus compounds, borax, hydrated alumina, graphite, potassium, silicon dioxide, tripolyphosphate, dipentaerythritol, pentaerythritol and polyols. Other flame retardant materials may also be used, such as nitrogen-containing phosphonates, monoammonium phosphate, ammonium polyphosphate, ammonium bromide, ammonium borate, ammonium borate ethanolammonium, ammonium sulfamate, halogenated organic compounds, thiourea and antimony oxide. In various aspects of the flame retardant materials, flame retardant materials and / or anti-scorch materials of the substrate material and / or other components (whether used alone or in combination with each other and / or with other materials), the desired properties are independent of and can resist undesirable degassing or melting-type behavior. Various ways and methods of incorporating tobacco into smoking articles, particularly smoking articles that are designed not to intentionally burn substantially all of the tobacco in those smoking articles, are described in U.S. Pat. No. 4,947,874 to Brooks et al.; U.S. Pat. No. 7,647,932 to Cantrell et al.; U.S. Pat. No. 8,079,371 to Robinson et al.; U.S. Pat. No. 7,290,549 to Banerjee et al.; and U.S. Patent Application Publication No. 2007 / 0215167 to Crooks et al.; which are incorporated herein by reference.

[0149] As described above, substrate portion 110 may also include conductive fibers or particles for heat conduction or heating by induction. In some embodiments, the conductive fibers or particles may be arranged in a substantially linear and parallel pattern. In some embodiments, the conductive fibers or particles may have a substantially random arrangement. In some embodiments, the conductive fibers or particles may be composed of one or more of an aluminum material, a stainless steel material, a copper material, a carbon material, and a graphite material. In some embodiments, one or more conductive fibers or particles having different Curie temperatures may be included in the substrate material to facilitate heating by induction at different temperatures.

[0150] In some embodiments, the substrate further comprises one or more binders. In some embodiments, the one or more binders are selected from: alginate / ester, cellulose derivatives, starch, gum, dextran, carrageenan, calcium carbonate or a combination thereof. Other examples of binder materials are described in the following documents: for example, U.S. Patent No. 5,101,839 of Jakob et al.; U.S. Patent No. 4,924,887 of Raker et al., which are incorporated herein by reference in their entirety.

[0151] In some embodiments, one or more binder materials are alginates, for example, ammonium alginate, 1,2-propylene glycol alginate, esters, potassium alginate and sodium alginate. Alginates and particularly high viscosity alginates can be used in combination with controlled levels of free calcium ions. In some embodiments, based on the weight basis, the substrate comprises about 0% to about 10% alginate, for example, about 0%, about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9% or about 10% alginate.

[0152] In some embodiments, the one or more binders are or include one or more cellulose derivatives (e.g., a single cellulose derivative or a combination of multiple (e.g., two or three) cellulose derivatives). In some embodiments, the substrate comprises from about 0% to about 5% of one or more cellulose derivatives, such as about 0%, about 1%, about 2%, about 3%, about 4%, or about 5% of one or more cellulose derivatives, on a weight basis. It should be understood that in embodiments where the substrate comprises more than one cellulose derivative, the weight basis of about 0% to about 5% of the one or more cellulose derivatives reflects the total weight of the combination of cellulose derivatives.

[0153] In some embodiments, cellulose derivatives include nano cellulose materials. As used herein, "nano cellulose materials" refers to at least one average particle size of about 1nm to about 100nm of cellulose materials. Although larger cellulose materials can be used, the reduction of aerosol-forming material loading may be caused. As a non-limiting example, suitable nano cellulose materials can be fibrous materials prepared by any variety of cellulose-containing materials, such as wood (such as eucalyptus), grass (such as bamboo), cotton, tobacco, algae and other plant-based materials, wherein the fiber is further refined, thereby producing nano fibrillated cellulose fibers. In various embodiments, nano cellulose materials can include one or more tobacco-derived nano cellulose fibers and / or non-tobacco-derived nano cellulose fibers, which are optionally combined with one or more additional cellulose materials, such as tobacco-derived cellulose pulp and / or cellulose fibers based on wood pulp. In some embodiments, binder materials can include the nano cellulose derived from tobacco or other biomass.

[0154] In some embodiments, one or more cellulose derivatives are chemically modified cellulose derivatives. Suitable chemically modified binder materials include: hydroxypropyl cellulose, such as Klucel H from Aqualon Co.; hydroxypropyl methyl cellulose, such as Methocel K4MS from The Dow Chemical Co.; hydroxyethyl cellulose, such as Natrosol 250MRCS from Aqualon; microcrystalline cellulose, such as Avicel from FMC; methyl cellulose, such as Methocel A4M from The Dow Chemical Co.; and sodium carboxymethyl cellulose, such as CMC 7HF and CMC 7H4F from Hercules Inc.

[0155] In some embodiments, one or more binding agents are starch. In some embodiments, based on the weight basis, the substrate comprises about 0% to about 30% starch or about 0% to about 15% starch or about 20% to about 40% starch. In some embodiments, for example, the substrate comprises about 0%, about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35% or about 40% starch. Suitable starch includes corn starch, rice starch and modified food starch. In some other embodiments, the binding agent is rice starch. In some embodiments, one or more binding agents are dextran. In some other embodiments, the binding agent can include cyclodextrin.

[0156] In some embodiments, the one or more binders are gums. Suitable gums include xanthan gum, guar gum, gum Arabic, locust bean gum, and gum tragacanth.

[0157] In some embodiments, the one or more binders is carrageenan.

[0158] In some embodiments, the one or more binders are calcium carbonate. In some embodiments, the substrate comprises about 0% to about 60% calcium carbonate on a weight basis; or about 45% to about 60% calcium carbonate; about 40% to about 60% calcium carbonate; or about 5% to about 15% calcium carbonate. In some embodiments, for example, the substrate comprises about 0%, about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, or about 60% calcium carbonate.

[0159] In some embodiments, the substrate comprises, on a weight basis: about 0% to about 60% calcium carbonate; about 0% to about 10% alginate; about 0% to about 5% one or more cellulose derivatives; about 0% to about 30% starch; about 0% to about 5% wood pulp; and about 0% to about 80% tobacco-derived fibers.

[0160] In some embodiments, the substrate comprises, on a weight basis: from about 0% to about 5% calcium carbonate; from about 1% to about 5% wood pulp; and from about 70% to about 80% tobacco-derived fibers.

[0161] In some embodiments, the substrate comprises, on a weight basis: about 45% to about 60% calcium carbonate; about 0% to about 10% alginate; about 0% to about 5% one or more cellulose derivatives; about 0% to about 15% starch; about 0% to about 5% wood pulp; and about 0% to about 40% tobacco-derived fibers.

[0162] In some embodiments, the substrate comprises, on a weight basis: about 40% to about 60% calcium carbonate; about 0% to about 10% alginate; about 0% to about 5% one or more cellulose derivatives; about 0% to about 15% starch; about 0% to about 5% wood pulp; and about 0% to about 40% tobacco-derived fibers.

[0163] In some embodiments, the substrate comprises, on a weight basis: about 5% to about 15% calcium carbonate; about 1% to about 5% one or more cellulose derivatives; about 20% to about 40% starch; and about 20% to about 40% tobacco-derived fibers.

[0164] In some embodiments, the substrate comprises tobacco-derived fibers, wood-derived fibers, or a combination thereof; and one or more binders. In some embodiments, the one or more binders are selected from the group consisting of alginates, cellulose derivatives, starches, gums, dextran, carrageenan, calcium carbonate, or a combination thereof.

[0165] In some embodiments, the substrate comprises, on a weight basis: about 40% to about 70% by weight tobacco-derived fibers; about 10% to about 15% by weight cellulose derivatives; and about 5% to about 10% by weight wood pulp. In some embodiments, the cellulose derivative is carboxymethyl cellulose.

[0166] The moisture (e.g., water) content of the substrate can vary. In some embodiments, the substrate further comprises up to about 10% by weight of water based on the total dry weight of the impregnated substrate (e.g., the substrate comprises the aerosol-forming material after drying to remove excess water added during processing).

[0167] In some embodiments, the substrate is in the form of particles, shredded forms, films, paper processed sheets, cast sheets, beads, granules, rods, or extrudates. In various embodiments, the substrate portion 110 may be in the form of gels, filaments, films, suspensions, extrudates, shavings, capsules, and / or granules (including pellets, beads, strips, or any desired granule shapes of varying sizes) and combinations thereof. In some embodiments, the substrate is formed into a substantially cylindrical shape.

[0168] In some embodiments, the substrate is prepared using paper processing technology, and the resulting sheet can be further reduced to cut pieces (rag) or strips to be inserted into the substrate-containing section of the aerosol delivery device. The preparation method generally includes hot water extraction (60-90°C) of tobacco leaves, stems, scraps or powder for a period of time. Subsequently, it can be separated (centrifuged and / or filtered) into a thin extract containing solubles and a solid part containing unrefined fibers. Then, the thin extract can be concentrated into an extract of>20% solid (w / v) by, for example, vacuum evaporation or other means. Optionally, one or more of two or more aerosol forming agents disclosed herein can be added and fully mixed to obtain a uniform mixture. Water and pre-pulped wood fibers can be added to tobacco solids, and the material can be refined again to fibrillate tobacco fibers. Refined tobacco slurry can then be produced nonwoven webs (web) or paper by a fourdrinier paper machine screen. The web can then be dried to a moisture content of 45-55%. The concentrated extract containing optional aerosol forming materials may then be added back to the web and dried to 8-10% moisture. Optionally, an inert filter aid may be added to the pulp prior to forming the web on the Fourdrinier screen.

[0169] In a second embodiment, cast sheet technology can be used to make flat sheets. Cast sheets typically include a binder material, an inert filler, optionally one or more of two or more aerosol forming agents, wood-derived fibers, and optionally botanicals, active ingredients, and / or tobacco or tobacco-derived materials, each as described herein. For example, in some embodiments, a fibrous material, one or more of two or more aerosol forming materials disclosed herein, and a binder can be blended together to form a slurry that can be cast onto a surface (e.g., a moving belt). The cast slurry can then undergo one or more drying and / or scraping steps to result in a cast sheet of relatively consistent thickness. Other examples of casting / casting and papermaking techniques are described in U.S. Pat. No. 4,674,519 to Keritsis et al.; U.S. Pat. No. 4,941,484 to Clapp et al.; U.S. Pat. No. 4,987,906 to Young et al.; U.S. Pat. No. 4,972,854 to Kiernan et al.; U.S. Pat. No. 5,099,864 to Young et al.; U.S. Pat. No. 5,143,097 to Sohn et al.; U.S. Pat. No. 5,159,942 to Brinkley et al.; U.S. Pat. No. 5,322,076 to Brinkley et al.; U.S. Pat. No. 5,339,838 to Young et al.; U.S. Pat. No. 5,377,698 to Litzinger et al.; U.S. Pat. No. 5,501,237 to Young; and U.S. Pat. No. 6,216,706 to Kumar; the disclosures of which are incorporated herein by reference in their entirety. In some embodiments, the flat sheet can be further reduced into cut pieces or strips for insertion into a substrate-containing section of an aerosol delivery device. The cast sheet can also be collected or rolled into a stick for insertion into a substrate-containing section of an aerosol delivery device.

[0170] In a third embodiment, the substrate can be prepared by granular extrusion followed by spheronization or pelletization to produce round or oval shaped beads or hair-like rods. Granular extrusion formulations are similar to cast sheet formulations except that alternative or additional binders (e.g., cellulose derivatives) are used.

[0171] In a fourth embodiment, the substrate can be prepared by extrusion followed by cutting or sizing to provide a variety of size and / or shape substrate pieces. The extrusion formulation is similar to the granular extrusion formulation except that another binder combination (eg, a combination of cellulose derivatives) is used.

[0172] In any of the foregoing embodiments, the entire amount of aerosol-forming material may be added prior to pouring / casting, extrusion, etc. to form the aerosol-generating component disclosed herein. Alternatively, or in addition, a portion or all of the aerosol-forming material may be impregnated into the substrate after formation (e.g., one or more aerosol-forming materials may be sprayed or otherwise disposed in or on the substrate material to form the aerosol-generating component as disclosed herein).

[0173] Figure 3 A perspective schematic diagram of an aerosol generating component according to an exemplary embodiment of the present disclosure is shown. Specifically, Figure 3 An aerosol generating component 104 is shown having a substrate portion 110 that includes a series of overlapping layers 130 of a sheet-form substrate 120. Referring to the above description, in the depicted embodiment, the substrate sheet 120 includes a film or layer as disclosed herein. In various embodiments, the term "overlapping layers" may also include bundled, wrinkled, curled and / or otherwise gathered layers, where the individual layers may not be apparent.

[0174] For example, Figure 4 1 shows a schematic cross-sectional view of a substrate portion of an aerosol generating component according to an exemplary embodiment of the present disclosure. Specifically, Figure 4 A substrate portion 110 is shown comprising a series of overlapping layers 130 of a substrate sheet 120. In the depicted embodiment, at least a portion of the overlapping layers 130 are substantially surrounded around their outer surfaces by a first cover layer 132. Although the composition of the first cover layer 132 may vary in various embodiments, in the depicted embodiment, the first cover layer 32 comprises a combination of a fibrous material, an aerosol-forming material, and a binder material. Reference is made to the discussion herein regarding possible aerosol-forming materials and binder materials.

[0175] In various embodiments, the first cover layer 132 may be constructed by a casting process, such as described in US Pat. No. 5,697,385 to Seymour et al., the disclosure of which is incorporated herein by reference in its entirety.

[0176] In the depicted embodiment, at least portions of the overlapping layer 130 and the first cover layer 132 are substantially surrounded around the outer surfaces by the second cover layer 134. Although the composition of the second cover layer 134 may vary, in the depicted embodiment, the second cover layer 134 comprises a metal foil material (such as an aluminum foil material). In other embodiments, the second cover layer may comprise other materials, including but not limited to copper materials, tin materials, gold materials, alloy materials, ceramic materials or other thermally conductive amorphous carbon-based materials, and / or any combination thereof. The depicted embodiment further includes a third cover layer 136 that substantially surrounds the outer surfaces of the overlapping layer 130, the first cover layer 132, and the second cover layer 134. In the depicted embodiment, the third cover layer 136 comprises a paper material (such as traditional cigarette wrapping paper). In various Implementation In some embodiments, the paper material may include shredded fibers, such as non-wood plant fibers, and may include flax, hemp, sisal, straw and / or esparto fibers.

[0177] Aerosol forming materials

[0178] The aerosol generating component disclosed herein includes a substrate, and the substrate is impregnated with two or more aerosol-forming materials, and the two or more aerosol-forming materials impregnated include: a first aerosol-forming material and a second aerosol-forming material, wherein the first aerosol-forming material and the second aerosol-forming material each have a different boiling point and / or a different vapor pressure. As used herein, "boiling point" refers to the temperature at which the vapor pressure of a liquid is equal to the pressure surrounding the liquid and the liquid becomes vapor. When the boiling point is mentioned herein, the pressure surrounding the liquid involved is standard atmospheric pressure (i.e., 760 mm Hg).

[0179] Without being bound by theory, it is believed that the presence of two or more different aerosol-forming materials, each having a different volatility (e.g., boiling point), allows for more control over aerosol formation when used in an aerosol-generating device. Controlling the volume and density of the aerosol by using two or more aerosol-forming materials, as well as optimizing the aerosol formation time of the aerosol-generating device relative to the application of heat, can result in an enhanced consumer experience relative to the use of a single aerosol-forming material. For example, a combination of two or even three or more different aerosol-forming materials with different volatiles can provide more consistent aerosol delivery throughout the use of a device or article that includes such a mixture of aerosol-generating materials. Specifically, when the articles or devices described herein are used, such a combination can provide less variation in the amount of aerosol produced from one puff to the next.

[0180] In addition, it has been found according to the present disclosure that the physical properties of the substrate are affected by the properties of the aerosol-forming material loaded therein. For example, it has been found that certain polyols, or mixtures of aerosol-forming materials comprising polyols, can increase the flexibility of the substrate. In contrast, certain other aerosol-forming materials (e.g., palmitic acid in the absence of polyols) provide a brittle and difficult to process substrate. Therefore, the selection of aerosol-forming materials or appropriate combinations thereof can be used to avoid brittleness while providing consistent and durable aerosol formation when loaded into a substrate and subjected to heating, such as in an aerosol generating device disclosed herein.

[0181] In some embodiments, the aerosol-forming materials each have a different boiling point, wherein the boiling point ranges from about 100°C to about 1000°C, for example, about 100°C, about 150°C, about 200°C, about 250°C, about 300°C, or about 350°C to about 400°C, about 500°C, about 600°C, about 700°C, about 800°C, about 900°C, or about 1000°C. In some embodiments, the boiling point of the first aerosol-forming material is about 100°C, about 125°C, about 150°C, or about 175°C to about 200°C, about 225°C, or about 250°C; and the boiling point of the second aerosol-forming agent is about 250°C, about 275°C, about 300°C, about 325°C, or about 350°C. In some embodiments, the difference in boiling point between the first and second aerosol-forming materials is at least 50°C or at least 100°C. In some embodiments, the difference in boiling points between the first and second aerosol-forming materials is about 50°C to about 300°C, such as about 50°C, about 100°C, about 150°C, about 200°C, about 250°C, or about 300°C.

[0182] The first and second aerosol-forming materials may be present in different proportions, with either component predominating depending on the intended application. In some embodiments, the aerosol-forming material is present in a weight ratio of the first aerosol-forming material to the second aerosol-forming material of about 100:1 to about 1:100, for example, about 100:1, about 95:5, about 90:10; about 80:20, about 70:30, about 60:40, about 50:50; about 40:60, about 30:70, about 20:80, about 10:90; 5:95, or about 1:100. In some embodiments, the aerosol-forming material is present in a weight ratio of the first aerosol-forming material to the second aerosol-forming material of about 10:1 to about 1:10, about 9:1 to about 1:9, about 8:2 to about 2:8, about 7:3 to about 3:7, about 6:4 to about 4:6, or about 1:1. In some embodiments, the aerosol-forming material is present in a weight ratio of the first aerosol-forming material to the second aerosol-forming material of about 3:1 to about 1:3. In some embodiments, the weight ratio of the first aerosol-forming material to the second aerosol-forming material is about 3:1, about 2:1, about 1:1, about 1:2, or about 1:3. In some embodiments, the weight ratio of the first aerosol-forming material to the second aerosol-forming material is about 1:1.

[0183] In some embodiments, the substrate is further impregnated with at least one additional aerosol-forming material. The boiling point of the additional aerosol-forming material can be in the same range as the first aerosol-forming material or the second aerosol-forming material, or can have a different boiling point range. For example, in one non-limiting embodiment, the boiling points of the first and second aerosol layer materials can be below 350°C, and the boiling point of the additional aerosol-forming material can be above about 350°C. In another non-limiting embodiment, the boiling points of the first and second aerosol layer materials can be above about 175°C, and the boiling point of the additional aerosol-forming material can be below about 175°C. In another non-limiting embodiment, the boiling points of the first and second aerosol layer materials can be from about 175°C to about 300°C, and the boiling point of the additional aerosol-forming material can be below about 175°C or above about 300°C.

[0184] In some embodiments, the first aerosol-forming material and the second aerosol-forming material and any additional aerosol-forming materials that may be present are each independently selected from the group consisting of water, polyols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, triacetin, waxes, triacetin, terpenes and sugar alcohols.

[0185] In some embodiments, the aerosol-forming material comprises one or more polyols. Examples of polyols include glycerol, 1,2-propylene glycol, and other glycols, such as 1,3-propylene glycol, diethylene glycol, triethylene glycol, and polyethylene glycol (e.g., PEG molecules with a weight average molecular weight ranging from about 200 to about 2000 Da).

[0186] In some embodiments, the aerosol forming material comprises one or more polysorbates. The example of polysorbate includes: polysorbate 60 (polyoxyethylene (20) sorbitan monostearate, Tween 60) and polysorbate 80 (polyoxyethylene (20) sorbitan monooleate, Tween 80). The type of polysorbate used or the combination of polysorbates used depends on the desired expected effect, because different polysorbates provide different properties due to molecular size. For example, the polysorbate molecular size can be increased from polysorbate 20 to polysorbate 80. Using smaller-sized polysorbate molecules produces less steam volume, but allows deeper lung penetration. When the user is in a public place and does not want to produce a large amount of "smoke" (such as steam), this may be desirable. On the contrary, if it is necessary to transmit the dense steam composed of tobacco aroma, larger polysorbate molecules can be used. Another benefit of using polysorbate family compounds is that polysorbate reduces the heat of evaporation of the mixture in which it exists.

[0187] In some embodiments, the aerosol-forming material comprises one or more sorbitan esters. Examples of sorbitan esters include sorbitan monolaurate, sorbitan monostearate (Span 60), sorbitan monooleate (Span 20), and sorbitan tristearate (Span 65).

[0188] In some embodiments, the aerosol-forming material comprises one or more fatty acids. The fatty acids may include short-chain, long-chain, saturated, unsaturated, straight-chain or branched carboxylic acids. The fatty acids generally include C 4 To C 28 Aliphatic carboxylic acids. Non-limiting examples of short-chain or long-chain fatty acids include butyric acid, propionic acid, valeric acid, oleic acid, linoleic acid, stearic acid, myristic acid, and palmitic acid. In some embodiments, the aerosol-forming material comprises one or more palmitic acids.

[0189] In some embodiments, the aerosol-forming material comprises one or more fatty acid esters. Examples of fatty acid esters include alkyl esters, monoglycerides, diglycerides, and triglycerides. Examples of monoglycerides include glyceryl monolaurate and glyceryl monostearate. Examples of triglycerides include glyceryl trioleate, glyceryl tripalmitate, tristearate, glyceryl tributyrate, and glyceryl tricaproate.

[0190] In some embodiments, the aerosol-forming material comprises one or more waxes. Examples of waxes include carnauba wax, beeswax, candellila wax, which are known to stabilize aerosol particles, improve palatability, or reduce throat irritation.

[0191] In some embodiments, the aerosol-forming material comprises one or more terpenes. As used herein, the term "terpene" refers to a hydrocarbon compound produced by plants from the biosynthesis of isopentenyl pyrophosphate. Non-limiting examples of terpenes include limonene, pinene, farnesene, and cembrene.

[0192] In some embodiments, the aerosol forming material comprises one or more sugar alcohols. Examples of sugar alcohols include sorbitol, erythritol, mannitol, maltitol, isomalt and xylitol. Sugar alcohols can also be used as flavor enhancers for certain flavor compounds, such as menthol and other volatiles, and generally improve the mouthfeel, texture (tactilesensation), throat impact and other organoleptic properties of the resulting aerosol.

[0193] In some embodiments, at least one of the first aerosol generating material and the second aerosol generating material is a polyol. In some embodiments, both the first aerosol forming material and the second aerosol forming material are polyols. In some embodiments, the polyols are glycerol and 1,2-propylene glycol. Glycerol and 1,2-propylene glycol may be present in different proportions, with either component dominating depending on the intended application, as disclosed above. For example, in some embodiments, glycerol and 1,2-propylene glycol are present in a weight ratio of about 3:1 to about 1:3. In some embodiments, glycerol and 1,2-propylene glycol are present in a weight ratio of about 3:1, about 2:1, about 1:1, about 1:2, or about 1:3. In some embodiments, glycerol and 1,2-propylene glycol are present in a weight ratio of about 1:1.

[0194] In some embodiments, the substrate is also impregnated with at least one other aerosol former. In some embodiments, the additional at least one other aerosol former is selected from the group consisting of water, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, triacetin, sugar alcohols, terpenes, and combinations thereof, each as described above. In some embodiments, the first aerosol-forming material is glycerol, the second aerosol-forming material is 1,2-propylene glycol, and the additional at least one additional aerosol former is water. In some embodiments, the first aerosol-forming material is glycerol, the second aerosol-forming material is 1,3-propylene glycol, and the additional at least one additional aerosol former is water. In some embodiments, the first aerosol-forming material is glycerol, the second aerosol-forming material is 1,2-propylene glycol, and the additional at least one additional aerosol former is polysorbates. In some embodiments, the first aerosol-forming material is glycerol, the second aerosol-forming material is a sugar alcohol, and the additional at least one additional aerosol former is water.

[0195] In some embodiments, the substrate is impregnated with two or more aerosol-forming materials, the two or more aerosol-forming materials comprising:

[0196] a first aerosol-forming material selected from the group consisting of glycerol, 1,2-propylene glycol, 1,3-propylene glycol, diethylene glycol, triethylene glycol, polyethylene glycol, glyceryl triacetate, and combinations thereof; and

[0197] a second aerosol-forming material selected from the group consisting of polysorbates, sorbitan esters, fatty acids, fatty acid esters, 1,3-propylene glycol, triethylene glycol, polyethylene glycol, triacetin, waxes, terpenes, and sugar alcohols;

[0198] The first aerosol-forming material and the second aerosol-forming material each have a different boiling point, a different vapor pressure, or a different boiling point and a different vapor pressure.

[0199] In some embodiments, the first aerosol-forming material is glycerol. In some embodiments, the first aerosol-forming material is 1,3-propylene glycol, triethylene glycol, 1,2-propylene glycol, or triacetin.

[0200] In some embodiments, the second aerosol-forming material is 1,3-propylene glycol, triethylene glycol, palmitic acid, or triacetin. In some embodiments, the second aerosol-forming material is selected from the group consisting of palmitic acid, polyethylene glycol 400, sorbitan tristearate, polysorbate 80, and combinations thereof.

[0201] In some embodiments, the first aerosol-forming material is glycerol and the second aerosol-forming material is 1,3-propylene glycol, triethylene glycol, palmitic acid, or glyceryl triacetate.

[0202] In some embodiments, the first aerosol-forming material is 1,3-propylene glycol, triethylene glycol, 1,2-propylene glycol, or triacetin, and the second aerosol-forming material is palmitic acid, polyethylene glycol 400, sorbitan tristearate, or polysorbate 80.

[0203] In some embodiments, the first aerosol-forming material is glycerol and the second aerosol-forming material is palmitic acid. In some embodiments, glycerol and palmitic acid are present in a weight ratio of about 100:1 to about 1:100, for example, about 100:1, about 95:5, about 90:10; about 80:20, about 70:30, about 60:40, about 50:50; about 40:60, about 30:70, about 20:80, about 10:90; 5:95, or about 1:100. In some embodiments, glycerol and palmitic acid are present in a weight ratio of about 3:1, about 2:1, about 1:1, about 1:2, or about 1:3. In some embodiments, palmitic acid is replaced by one of the listed aerosol formers, including but not limited to 1,3-propylene glycol, triethylene glycol, triacetin, polyethylene glycol, or polysorbate 60.

[0204] In some embodiments, the substrate is impregnated with three aerosol forming agents. The ratio of the three aerosol forming materials can vary. Thus, any of the three aerosol forming agents can be present in any ratio relative to each of the other two aerosol forming materials. In some embodiments, the three aerosol forming agents are present in approximately equal amounts. In some embodiments, there is more of one aerosol forming agent relative to the other two aerosol forming agents. In a specific embodiment, the three aerosol forming agents are present in a weight ratio of 1:1.5:1.5.

[0205] In some embodiments, the substrate is impregnated with glycerol, palmitic acid, and a third aerosol-forming material selected from the group consisting of 1,3-propylene glycol, triethylene glycol, 1,2-propylene glycol, glyceryl triacetate, polyethylene glycol 400, sorbitan tristearate, and polysorbate 80.

[0206] In some embodiments, the substrate is impregnated with glycerol, palmitic acid, and 1,3-propylene glycol. In some embodiments, glycerol, palmitic acid, and 1,3-propylene glycol are present in a weight ratio of about 1:1.5:1.5.

[0207] In some embodiments, the substrate is impregnated with glycerol, palmitic acid, and triethylene glycol. In some embodiments, the substrate is impregnated with glycerol, palmitic acid, and triethylene glycol in a weight ratio of 1:1.5:1.5.

[0208] In some embodiments, the substrate is impregnated with glycerol, palmitic acid, and 1,2-propylene glycol. In some embodiments, the substrate is impregnated with glycerol, palmitic acid, and 1,2-propylene glycol in a weight ratio of 1:1.5:1.5.

[0209] In some embodiments, the substrate is impregnated with glycerol, palmitic acid, and triacetin. In some embodiments, the substrate is impregnated with glycerol, palmitic acid, and triacetin in a weight ratio of 1:1.5:1.5.

[0210] In some embodiments, the substrate is impregnated with glycerol, palmitic acid, and polyethylene glycol 400. In some embodiments, the substrate is impregnated with glycerol, palmitic acid, and polyethylene glycol 400 in a weight ratio of 1:1.5:1.5.

[0211] In some embodiments, the substrate is impregnated with glycerol, palmitic acid, and sorbitan tristearate. In some embodiments, the substrate is impregnated with glycerol, palmitic acid, and sorbitan tristearate in a weight ratio of 1:1.5:1.5.

[0212] In some embodiments, the substrate is impregnated with glycerol, palmitic acid, and polysorbate 80. In some embodiments, the substrate is impregnated with glycerol, palmitic acid, and polysorbate 80 in a weight ratio of 1:1.5:1.5.

[0213] In some embodiments, the substrate is impregnated with four aerosol forming agents. The ratio of the four aerosol forming materials can vary. In a specific embodiment, the four aerosol forming agents are present in a weight ratio of 2:1:1:0.5.

[0214] In some embodiments, the substrate is impregnated with glycerol, palmitic acid, 1,3-propylene glycol, and triacetin. In some embodiments, the substrate is impregnated with glycerol, palmitic acid, 1,3-propylene glycol, and triacetin in a weight ratio of 1:0.5:2:1.

[0215] In some embodiments, the substrate is loaded with (e.g., combined with or impregnated with) an aerosol-forming material as described herein. The amount of aerosol-forming material combined (loaded) in the substrate is such that the aerosol-generating component provides acceptable sensory and desired performance characteristics. For example, it is highly preferred to use a sufficient amount of aerosol-forming material to provide the generation of a visible primary aerosol flow that is similar in many respects to the appearance of tobacco smoke. The amount of forming material in the aerosol-generating component (e.g., an impregnated substrate) can depend on a variety of factors, such as the number of puffs required per aerosol-generating component.

[0216] In some embodiments, the substrate is impregnated with an aerosol-forming material at a loading of at least about 5 wt%, at least about 10 wt%, at least about 15 wt%, at least about 20 wt%, at least about 25 wt%, at least about 30 wt%, at least about 35 wt%, at least about 40 wt%, at least about 45 wt%, at least about 50 wt%, at least about 55 wt%, or at least about 60 wt%, based on the total weight of the impregnated substrate. Exemplary ranges of aerosol-forming material include about 5% to about 60%, about 10% to about 50%, or about 20% to about 40%, such as about 15% to about 55%, about 15% to about 30%, or about 15% to about 25%, based on the total weight of the impregnated substrate. Methods for loading aerosol-forming materials onto a substrate portion are described in U.S. Pat. No. 9,974,334 to Dooly et al., U.S. Patent Application Publication No. 2015 / 0313283 to Collett et al., and U.S. Patent Application Publication No. 2018 / 0279673 to Sebastian et al., the disclosures of which are incorporated herein by reference in their entirety.

[0217] In various embodiments, loading of aerosol-forming materials to a substrate is achieved by impregnating the substrate with an aerosol-forming material during the preparation of the substrate material and / or after formation. For example, in some embodiments, during, for example, sheet manufacturing, a first aerosol-forming material (e.g., 1,2-propylene glycol) is added to a substrate to form a slurry, and a second forming material (e.g., glycerol) is added to the sheet as a top dressing (e.g., by spraying) to form an impregnated substrate (i.e., an aerosol-generating component). In other embodiments, both the first aerosol-forming material and the second aerosol-forming material are added to the substrate to form a slurry. In some embodiments, other aerosol-forming materials may be impregnated in the substrate, or impregnated into the substrate to form a slurry or as a top dressing. As will be appreciated by those skilled in the art, various arrangements of methods for loading aerosol-forming materials to a substrate are possible, depending on the specific substrate material, form, etc. Therefore, any such changes are contemplated herein.

[0218] In some embodiments, the substrate is also impregnated with a flavorant, an active ingredient, or a combination thereof. Each of these components is further described below.

[0219] Active ingredients

[0220] In certain embodiments, the substrate is also impregnated with one or more active ingredients. The active ingredient may be a component of the aerosol-forming material, or may be impregnated separately. The impregnation may be performed during the preparation of the substrate material and / or after the substrate is formed.

[0221] As used herein, "active ingredient" refers to one or more substances belonging to any of the following categories: API (active pharmaceutical), food additives, natural medicines, and natural substances that have an effect on the human body. Example active ingredients include any ingredients known to affect one or more biological functions in the body, such as ingredients that provide pharmacological activity or other direct effects in the diagnosis, treatment, relief, treatment or prevention of a disease, or ingredients that affect the structure or any function of the human body (e.g., providing a stimulating effect on the central nervous system, having a refreshing effect, antipyretic or analgesic effect, or having other useful effects on the body). In some embodiments, the active ingredient can be a type commonly referred to as a dietary supplement, a nutrient, a "phytochemical" or a "functional food". These types of additives are sometimes defined in the art as including substances that are generally available from naturally occurring sources (e.g., plant materials) that provide one or more favorable biological effects (e.g., promoting health, preventing disease or other medicinal properties), but are not classified or specified as drugs.

[0222] The non-limiting examples of active ingredients include those falling into the following categories: synthetic organic compounds, proteins and peptides, polysaccharides and other sugars, lipids, inorganic compounds and nucleic acid sequences with therapeutic, preventive or diagnostic activity. The non-limiting examples of active ingredients include those falling into the following categories: plant ingredients, stimulants (such as caffeine and guarana), amino acids (such as taurine, theanine, phenylalanine, tyrosine and tryptophan) and / or medicines, nutrition and medicinal ingredients (such as vitamins, such as B6, B12 and C), antioxidants and nicotine ingredients. The specific selection of active ingredients will change according to the required flavor, texture and required characteristics of a particular product.

[0223] The specific percentage of active ingredient present will vary depending on the desired characteristics of a particular product. Typically, the active ingredient or combination thereof is present in a total concentration of at least about 0.001% by weight of the composition, such as about 0.001% by weight to about 20% by weight. In some embodiments, the active ingredient or combination of active ingredients is present in a concentration of about 0.1% w / w to about 10% by weight, such as about 0.5% w / w to about 10%, about 1% to about 10%, about 1% to about 5% by weight, based on the total weight of the composition. In some embodiments, the active ingredient or the combination of active ingredients is present at a concentration of about 0.001 wt %, about 0.01 wt %, about 0.1 wt %, or about 1 wt %, up to about 20 wt %, for example, about 0.001 wt %, about 0.002 wt %, about 0.003 wt %, about 0.004 wt %, about 0.005 wt %, about 0.006 wt %, about 0.007 wt %, about 0.008 wt %, about 0.009 wt %, about 0.01 wt %, about 0.02 wt %, about 0.03 wt %, about 0.04 wt %, about 0.05 wt %, about 0.06 wt %, about 0.07 wt %, about 0.08 wt %, about 0.09 wt %, about 0.01 wt %, about 0.02 wt %, about 0.03 wt %, about 0.04 wt %, about 0.05 wt %, about 0.06 wt %, about 0.07 wt %, about 0.08 wt %, about 0.09 wt %. %, about 15 wt %, about 16 wt %, about 17 wt %, about 18 wt %, about 19 wt %, about 20 wt %, about 21 wt %, about 22 wt %, about 23 wt %, about 24 wt %, about 25 wt %, about 26 wt %, about 27 wt %, about 28 wt %, about 29 wt %, about 30 wt %, about 31 wt %, about 32 wt %, about 33 wt %, about 34 wt %, about 35 wt %, about 36 wt %, about 37 wt %, about 38 wt %, about 39 wt %, about 40 wt %, about 41 wt %, about 42 wt %, about 43 wt %, about 44 wt %, about 45 wt %, about 46 wt %, about 47 wt %, about 48 wt %, about 49 wt %, about 50 wt %, about 51 wt %, about 52 wt %, about 53 wt %, about 54 wt %, about 55 wt %, about 56 wt %, about 57 wt %, about 58 wt %, about 59 wt %, about 60 wt %, about 61 wt %, about 62 wt %, about 63 wt %, about 64 wt %, about 65 wt %, about 66 wt %, about 67 wt %, about 68 wt %, about 69 wt %, about 70 wt %, about 71 wt %, about 72 wt %, about 73 wt %, about 74 wt %, about 75 wt %, about 76 wt %, about 77 wt %, about 78

[0224] Botanicals

[0225] In some embodiments, activity fully includes one or more non-tobacco botanicals.As used herein, term " plant ingredient " (botanical ingredient) or " plant medicine " (botanical) refer to any plant material or fungus derived material, including the plant material of its natural form and the plant material derived from natural plant material, such as extract or isolate (such as, through heat treatment, fermentation or other treatment processes that can change material chemistry) from plant material or processed plant material.For the purpose of this disclosure, " plant material " includes but is not limited to " herbal material ", it refers to the seed-producing plant (seed-producing plant) that does not produce continuous wood tissue, and is usually valued (such as, tea or herbal tea) because of its medicinal or organoleptic characteristics.Referred to as " non-tobacco " by plant material is to exclude tobacco material (that is, not including any Nicotiana species).The plant material used in the present invention can include but is not limited to any compound and source as described herein, including its mixture.Some of this type of plant material is sometimes referred to as dietary supplements, nutrition, " phytochemicals " or " functional food ".

[0226] Non-limiting examples of plant materials, many of which are associated with antioxidant properties, include, but are not limited to, acai berry, alfalfa, allspice, annatto seed, apricot oil, ashwagandha, bacopa monniera, baobab, basil, bee balm, beet root, wild bergamot, black pepper, blueberries, borage seed oil, bugleweed, cacao, calamus root, catnip, catuaba, cayenne pepper, Centella asiatica, chaga mushroom, Chai-hu, chamomile, cherry blossom, chervil, chlorophyll, cinnamon, dark chocolate, citrus, roasted cocoa, comfrey leaf and root, gingko biloba, ginseng, goji berries, grape seed, green tea, black tea, black cohosh, cayenne, chamomile, cloves, cocoa powder, cordyceps, cranberry, curcumin, damiana, dandelion, Dorstenia arifolia, Dorstenia odorata), echinacea, eucalyptus, fennel, feverfew, Galphimia glauca, garlic, ginger, ginseng (e.g.,Panax ginseng), goldenseal, green tea, grapefruit, Griffonia simplicifolia, guarana, gutu kola, hawthorn, hemp, hibiscus flower, honeybush,Hops, jasmine, jiaogulan, Kaempferia parviflora (Thai ginseng), kava, lavender, lemon balm, lemongrass, licorice, Lion's mane, lutein, maca, matcha, Nardostachys chinensis, marjoram, milk thistle, mints (menthe), oolong tea, orange, oregano, papaya, pennyroyal, peppermint, potato peel, primrose, quercetin, red clover clover, resveratrol, Rhizomagastrodiae, Rhodiola, rooibos, rooibos tea (rooibos black or green), rose essential oil, rosehip, rosemary, sage, clary sage, savory, saw palmetto, Sceletium tortuosum, Schisandra, silybummarianum, skullcap, spearmint, spikenard, spirulina, slippery elm bark, sorghum bran hi-tannin, sorghum grain hi-tannin, Saint John's wort John's Wort,sumac bran, terpenes, thyme, tisanes, turmeric, turnera aphrodisiaca, uva ursi, valerian, viola odorata, white mulberry, wild yam root, wintergreen, withania somnifera, yacon root, yellow dock, yerbamate, yerba santa,

[0227] When present, the concentration of the botanical is typically from about 0.01% w / w to about 10% by weight, such as from about 0.01%, about 0.05%, about 0.1%, or about 0.5% to about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, or about 10%, about 11%, about 12%, about 13%, about 14%, or about 15% by weight, based on the total weight of the composition.

[0228] Nicotine component

[0229] In some embodiments, the active ingredient includes a nicotine component. "Nicotine component" refers to nicotine in any suitable form (e.g., free alkali or salt) for providing systemic absorption of at least part of the nicotine. Nicotine sources can vary and can be natural or synthetic. Most preferably, nicotine is naturally occurring and obtained as an extract of a tobacco species (e.g., tobacco). Nicotine can have an enantiomeric form of S (-)-nicotine, R (+)-nicotine, or a mixture of S (-)-nicotine and R (+)-nicotine. Most preferably, nicotine is in the form of S (-)-nicotine (e.g., in fact, all in the form of S (-)-nicotine) or a mixture of enantiomers (e.g., a mixture consisting of about 95 parts by weight of S (-)-nicotine and about 5 parts by weight of R (+)-nicotine) mainly or substantially composed of S (-)-nicotine. Most preferably, nicotine is used in a substantially pure form or substantially pure form. Highly preferred nicotine is employed in a purity of greater than about 95%, more preferably greater than about 98%, and most preferably greater than about 99% by weight.

[0230] Typically, the nicotine component is selected from the group consisting of nicotine free base and nicotine salt. In some embodiments, nicotine is in the form of its free base. Nicotine can be tobacco-derived (e.g., tobacco extract) or non-tobacco-derived (e.g., synthetic or otherwise obtained). In various embodiments, the impregnated substrate may include a nicotine component. In various embodiments, the impregnated substrate may not include a nicotine component. In some embodiments, the impregnated substrate may include a non-tobacco-derived nicotine component.

[0231] Typically, the nicotine component (calculated as free base) is present at a concentration of at least about 0.001% by weight of the impregnated substrate, such as about 0.001% by weight to about 10% by weight. In some embodiments, the nicotine component is present at a concentration of about 0.1% w / w to about 10% by weight, such as about 0.1% w / w, about 0.2% by weight, about 0.3% by weight, about 0.4% by weight, about 0.5% by weight, about 0.6% by weight, about 0.7% by weight, about 0.8% by weight, or about 0.9% by weight, to about 1% by weight, about 2% by weight, about 3% by weight, about 4% by weight, about 5% by weight, about 6% by weight, about 7% by weight, about 8% by weight, about 9% by weight, or about 10% by weight, calculated as free base, based on the total weight of the impregnated substrate. In some embodiments, the nicotine component is present at a concentration of about 0.1% w / w to about 3% by weight, such as about 0.1% w / w to about 2.5%, about 0.1% to about 2.0%, about 0.1% to about 1.5% by weight, or about 0.1% to about 1% by weight, based on the total weight of the impregnated substrate, calculated as free base. These ranges may also apply to other active ingredients described herein.

[0232] In some embodiments, the substrate of the present disclosure can be characterized as being completely free of or substantially free of nicotine components. "Substantially free of nicotine components" means that no nicotine is intentionally added except for trace amounts of nicotine that may be naturally present in plant materials. For example, certain embodiments can be characterized as having less than 0.001% by weight of nicotine, or less than 0.0001% by weight, or even 0% by weight of nicotine, calculated as free base.

[0233] Terpenes

[0234] Active ingredients suitable for use in the present invention may also be classified as terpenes, many of which are associated with biological effects such as sedation. Terpenes are understood to have (C 5 H 8 ) nThe general formula of and includes monoterpenes, sesquiterpenes and diterpenes. The structure of terpenes can be acyclic, monocyclic or bicyclic. Examples include β-caryophyllene, linalool, limonene, β-citronellol, linalyl acetate, pinene (α or β), geraniol, carvone, eucalyptol, menthone, isomenthone, piperitone, myrcene, β-bourbonne and myrcene, which can be used alone or in combination.

[0235] In some embodiments, the terpene is a terpene that can be derived from a plant. Suitable terpenes in this regard include so-called "C10" terpenes, which are those containing 10 carbon atoms, and so-called "C15" terpenes, which are those containing 15 carbon atoms. In some embodiments, the active ingredient comprises more than one terpene. For example, the active ingredient may comprise one, two, three, four, five, six, seven, eight, nine, ten or more terpenes as defined herein. In some embodiments, the terpene is selected from pinene (α and β), geraniol, linalool, limonene, carvone, eucalyptol, menthone, isomenthone, piperitone, myrcene, β-bourbonne, myrcene and mixtures thereof.

[0236] Tobacco components

[0237] In some embodiments, active ingredient comprises tobacco component (for example tobacco extract).In various embodiments, tobacco material can be processed to extract therefrom the soluble component of tobacco material." tobacco extract " used herein refers to the separated component of the tobacco material extracted from the solid tobacco slurry by the solvent contacted with tobacco material in the extraction process.The various extraction techniques of tobacco material can be used for providing tobacco extract and tobacco solid material.Referring to the extraction techniques described in No. 2011 / 0247640 of the U.S. Patent Publication of for example Beeson et al., it is incorporated herein by reference.Other exemplary techniques for extracting tobacco components are described in: U.S. Pat. No. 4,144,895 to Fiore; U.S. Pat. No. 4,150,677 to Osborne, Jr. et al.; U.S. Pat. No. 4,267,847 to Reid; U.S. Pat. No. 4,289,147 to Wildman et al.; U.S. Pat. No. 4,351,346 to Brummer et al.; U.S. Pat. No. 4,359,059 to Brummer et al.; U.S. Pat. No. 4,506,682 to Muller; U.S. Pat. No. 4,589,428 to Keritsis; U.S. Pat. No. 4,605,017 to Soga et al. 6; U.S. Patent No. 4,716,911 to Poulose et al.; U.S. Patent No. 4,727,889 to Niven, Jr. et al.; U.S. Patent No. 4,887,618 to Bernasek et al.; U.S. Patent No. 4,941,484 to Clapp et al.; U.S. Patent No. 4,967,771 to Fagg et al.; U.S. Patent No. 4,986,286 to Roberts et al.; U.S. Patent No. 5,005,593 to Fagg et al.; U.S. Patent No. 5,018,540 to Grubbs et al.; U.S. Patent No. 5,060,669 to White et al.; U.S. Patent No. 5, 065,775; U.S. Patent No. 5,074,319 to White et al.; U.S. Patent No. 5,099,862 to White et al.; U.S. Patent No. 5,121,757 to White et al.; U.S. Patent No. 5,131,414 to Fagg; U.S. Patent No. 5,131,415 to Munoz et al.; U.S. Patent No. 5,148,819 to Fagg; U.S. Patent No. 5,197,494 to Kramer; U.S. Patent No. 5,230,354 to Smith et al.; U.S. Patent No. 5,234,008 to Fagg; U.S. Patent No. 5,243,999 to Smith; Raymond No. 5,301,694 to Gonzalez-Parra et al.; No. 5,318,050 to Gonzalez-Parra et al.; No. 5,343,879 to Teague; No. 5,360,022 to Newton; No. 5,435,325 to Clapp et al.; No. 5,445,169 to Brinkley et al.; No. 6,131,584 to Lauterbach; No. 6,298,859 to Kierulff et al.; No. 6,772,767 to Mua et al.; and No. 7,337,782 to Thompson, all of which are incorporated herein by reference.

[0238] The typical inclusion range of tobacco components can change according to the intended use of the property and type of tobacco material and aerosol generating parts.In some embodiments, the product of the present disclosure can be characterized as being completely free of or substantially free of tobacco components (except the nicotine as the purification of active ingredient).For example, some embodiments can be characterized as having less than 1 % by weight, or less than 0.5 % by weight, or less than 0.1 % by weight, or less than 0.01 % by weight of tobacco components, even 0 % by weight of tobacco components.

[0239] spices

[0240] As previously mentioned, the impregnated substrate may also include spices. The active ingredient may be a component of the aerosol-forming material, or may be impregnated separately. Impregnation may be performed during substrate material preparation and / or after substrate formation. As used herein, the "spice" mentioned refers to a compound or component that can be atomized and delivered to the user and imparts a sensory experience in taste and / or aroma. Spice may be natural or synthetic, and the properties of the spices thus imparted may be described as, but not limited to, fresh, sweet, herbal, confectionery, floral, fruity or spicy. Some examples of flavors include, but are not limited to, vanillin, ethyl vanillin, cream, tea, coffee, fruit (e.g., apple, cherry, strawberry, peach, and citrus flavors including lime, orange, and lemon), maple, menthol, eucalyptus, mint, peppermint, spearmint, wintergreen, cascarilla, nutmeg, clove, lavender, cardamom, ginger, honey, anise, sage, rosemary, hibiscus, rose hip, yerba mate, guayusa, honeybush, rooibos, yerba mate, guayusa, honeybush, rooibos, yerba mate, galangal, galangal, galangal, galangal, galangal, galangal, galangal, galangal, galangal, galangal, galangal, galangal, galangal, galangal, galangal, galangal, galangal, galangal, galangal, galangal, galangal, galangal, galangal, galangal, galangal As used herein, "trigeminal sensate" refers to a flavoring agent that acts on the trigeminal nerve to produce sensations including heating, cooling, tingling, etc. Non-limiting examples of trigeminal sensate flavoring agents include capsaicin, citric acid, menthol, Sichuan button, erythritol, and cubebol. Additional non-limiting examples include flavoring agents and flavoring packets of the type and nature of flavoring agents traditionally used for cigarettes, cigars, and pipe tobacco.See also Tobacco Flavoring for Smoking Products (tobacco flavoring of smoking products) of Leffingwell et al., RJ Reynolds Tobacco Company (1972), which is incorporated herein by reference. Flavoring agent (flavoring agent) can include components such as terpenes, terpenoids, aldehydes, ketones, esters. Syrups, such as high fructose corn syrup, can also be used. Some exemplary plant-derived compositions that may be suitable are disclosed in U.S. Patent No. 9,107,453 and U.S. Patent Publication No. 2012 / 0152265 of Dube et al., and its disclosure is incorporated herein by reference in full. Based on multiple factors (such as the required organoleptic properties of smoking articles, affinity for substrate materials, solubility and other physicochemical properties), the selection of such other components is variable. This disclosure is intended to cover any other components that are apparent to the technician in tobacco and tobacco-related or tobacco-derived product fields. For example, see Gutcho, "Tobacco Flavoring Substances and Methods", Noyes Data Corp. (1972) and Leffingwell et al., "Tobacco Flavoring for Smoking Products" (1972), the disclosure of which is incorporated herein by reference in its entirety. It should be noted that reference to flavorings should not be limited to any single flavoring as described above, and in fact may represent a combination of one or more flavorings. Additional spices and other possible flavor enhancers, additives and other possible enhancement components are described in U.S. Patent Application No. 15 / 707,461 to Phillips et al., which is incorporated herein by reference in its entirety.

[0241] The amount of fragrance present can vary, and when present, is generally less than about 30% by weight, or about 20% by weight of the impregnated substrate. For example, the fragrance can be present in an amount of about 0.1%, about 0.5%, about 1%, or about 5% by weight, to about 10%, about 20%, or about 30% by weight of the impregnated substrate.

[0242] Aerosol delivery devices

[0243] As described herein, in another aspect, an aerosol delivery device is provided, comprising: an aerosol generating component as disclosed herein; a heat source configured to heat an aerosol-forming material impregnated in a substrate to form an aerosol; and an aerosol path extending from the aerosol generating component to a mouthpiece end of the aerosol delivery device.

[0244] Although in some embodiments, the aerosol generating component and the control body can generally be provided together as a complete smoking article or a drug delivery device, these components can be provided separately. For example, the present disclosure also includes a disposable unit used in conjunction with a reusable smoking article or a reusable drug delivery article. In a specific embodiment, the disposable unit (which can be an aerosol generating component as shown in the accompanying drawings) can include a substantially tubular body having: a heating end configured to engage a reusable smoking article or a drug delivery article, a relative mouth end configured to allow inhalable material to flow to the consumer, and a wall having an outer surface and an inner surface that define an internal space. Various embodiments of the aerosol generating component (or cartridge) are described in U.S. Patent No. 9,078,473 to Worm et al., the entire contents of which are incorporated herein by reference.

[0245] Although some of the drawings described herein show the control body and the aerosol generating component in a working relationship, it should be understood that the control body and the aerosol generating component can exist as individual devices. Therefore, any discussion of the combined components herein should also be understood to apply to the control body and the aerosol generating component as individual and separate components.

[0246] In another aspect, the present disclosure may relate to a kit that provides various components described herein. For example, a kit may include a control body having one or more aerosol generating components. The kit may also include a control body and one or more charging components. The kit may also include a control body and one or more batteries. The kit may also include a control body and one or more aerosol generating components and one or more charging components and / or one or more batteries. In another embodiment, the kit may include multiple aerosol generating components. The kit may also include multiple aerosol generating components and one or more batteries and / or one or more charging components. In the above embodiment, the aerosol generating component or the control body may be provided with a heating member including the same. The kit of the present invention may also include a box (or other packaging, carrying or storage component) that accommodates one or more other kit components. The box may be a reusable hard or soft container. In addition, the box may simply be a box or other packaging structure.

[0247] Figure 5 shows a perspective view of an aerosol generating component according to another exemplary embodiment of the present disclosure; and Figure 6 Shown with the outer wrapping removed Figure 5 A perspective view of how aerosol generation occurs. Specifically, Figure 5 An aerosol generating component 200 including an outer wrapper 202 is shown, and Figure 6An aerosol generating component is shown with the outer wrapper 202 removed to reveal the other components of the aerosol generating component 200. In the illustrated embodiment, the aerosol generating component 200 of the illustrated embodiment includes a heat source 204, a substrate portion 210, an intermediate component 208, and a filter 212. In the illustrated embodiment, the intermediate component 208 and the filter 212 together include a mouthpiece portion 214.

[0248] Although the aerosol delivery device and / or aerosol generating component of the present disclosure can adopt various embodiments, as discussed in detail below, the range of uses of the aerosol delivery device and / or aerosol generating component by consumers will be similar. The above description of the use of the aerosol delivery device and / or aerosol generating component can be applied to the various embodiments described herein with minor modifications, which are obvious to those skilled in the art based on the other disclosures provided herein. However, the description of use is not intended to limit the use of the article of the present invention, but is intended to meet all necessary requirements of the disclosure herein.

[0249] In various embodiments, the heat source 204 can be configured to generate heat after it is ignited. In the illustrated embodiment, the heat source 204 includes a combustible fuel element having a generally cylindrical shape and containing a combustible carbonaceous material. In other embodiments, the heat source 204 can have a different shape, for example, a prism shape having a triangular, cubic, or hexagonal cross-section. The carbonaceous material typically has a high carbon content. Preferred carbonaceous materials can be primarily composed of carbon and / or have a carbon content of typically greater than about 60%, often greater than about 70%, often greater than about 80%, and often greater than about 90%, by dry weight.

[0250] In some cases, the heat source 204 may include elements other than combustible carbonaceous materials (e.g., tobacco ingredients, such as tobacco powder or tobacco extracts; flavorings; salts, such as sodium chloride, potassium chloride, and sodium carbonate; thermally stable graphite fibers; iron oxide powder; glass filaments; powdered calcium carbonate; aluminum oxide particles; ammonia sources, such as ammonia salts; binders, such as guar gum, ammonium alginate, and sodium alginate; and / or phase change materials for reducing the temperature of the heat source, as described above). Although the specific dimensions of a suitable heat source may vary, in some embodiments, the heat source 204 may range in length from about 7 mm to about 20 mm, and in some embodiments, may be about 17 mm, and may range in overall diameter from about 3 mm to about 8 mm, and in some embodiments may be about 4.8 mm (and in some embodiments, about 7 mm). Although in other embodiments, the heat source may be constructed in various ways, in the illustrated embodiment, the heat source 204 may be extruded or compounded using a ground or powdered carbonaceous material and may have a density of greater than about 0.5 g / cm on a dry weight basis. 3, usually greater than about 0.7 g / cm 3 , and often greater than about 1 g / cm 3 . See, for example, the types of fuel source components, formulations, and designs described in U.S. Patent No. 5,551,451 to Riggs et al. and U.S. Patent No. 7,836,897 to Borschke et al., which are incorporated herein by reference. Although in various embodiments, the heat source can have a variety of forms, including, for example, a substantially solid cylindrical or hollow cylindrical (e.g., tube) shape, the heat source 204 of the embodiments includes an extruded monolithic carbonaceous material having a generally cylindrical shape but having a plurality of grooves 216 extending longitudinally from a first end of the extruded monolithic carbonaceous material to an opposing second end of the extruded monolithic carbonaceous material. In some embodiments, the aerosol delivery device (particularly the heat source) can include a heat transfer component. In various embodiments, the heat transfer component can be proximate to the heat source, and in some embodiments, the heat transfer component can be located in or within the heat source. Some examples of heat transfer components are described in U.S. Patent Application No. 15 / 923,735, entitled Smoking Article with Heat Transfer Component, filed on March 16, 2018, which is incorporated herein by reference in its entirety.

[0251] Although in the depicted embodiment, the grooves 216 of the heat source 204 are substantially equal in width and depth and are substantially evenly distributed around the circumference of the heat source 204, other embodiments may include as few as two grooves, and other embodiments may include as few as a single groove. Other embodiments may not include grooves at all. Additional embodiments may include multiple grooves, which may have unequal widths and / or depths and may be unequally spaced around the circumference of the heat source. In other embodiments, the heat source may include grooves and / or slits extending longitudinally from a first end of an extruded monolithic carbonaceous material to an opposite second end thereof. In some embodiments, the heat source may include a foamed carbon monolith formed by a foaming process of the type disclosed in U.S. Patent No. 7,615,184 to Lobovsky, which is incorporated herein by reference in its entirety. Therefore, some embodiments may provide advantages related to reducing the time it takes to ignite a heat source. In some other embodiments, the heat source may be co-extruded with a layer of insulation (not shown), thereby reducing manufacturing time and cost. Other embodiments of the fuel element include carbon fibers of the type described in US Pat. No. 4,922,901 to Roberts et al., or other heat source embodiments such as disclosed in US Patent Application Publication No. 2009 / 0044818 to Takeuchi et al., each of which is incorporated herein by reference in its entirety.

[0252] Typically, the heat source is sufficiently close to the aerosol generating portion (e.g., substrate portion) having one or more aerosolizable components so that the aerosol can be delivered to the user through the mouthpiece by heat from the heat source to the aerosolizable components (as well as any flavorants, drugs, and / or the like that are also provided for delivery to the user. That is, when the heat source heats the substrate portion, the aerosol is formed, released, or generated in a physical form suitable for inhalation by the consumer. It should be noted that the above terms are meant to be interchangeable, so that references to release, releasing, released, or released include forming or generating, forming or generating, forming or generating, and being formed or generated. Specifically, the inhalable substance is released in the form of a vapor or an aerosol or a mixture thereof. In addition, considering commercially available electronic aerosol delivery devices, such as those representative products listed in the background technology section of the present disclosure, the selection of various aerosol delivery product elements / components can be understood.

[0253] Return to reference Figure 5 and Figure 6 , an outer wrap 202 may be provided to engage or otherwise couple at least a portion of the heat source 204 with the substrate portion 210 and at least a portion of the mouthpiece portion 214. In various embodiments, the outer wrap 202 is configured to be retained in a wrapped position in any manner, including by adhesives or fasteners, etc., allowing the outer wrap 202 to remain in a wrapped position. Otherwise, in some other aspects the outer wrap 202 may be configured to be removable as desired. For example, the outer wrap 202 may be removable from the heat source 204, the substrate portion 210, and / or the mouthpiece portion 214 while the outer wrap 202 is retained in a wrapped position.

[0254] In some embodiments, in addition to the outer wrapper 202, the aerosol delivery device may also include a substrate configured to surround at least a portion of the substrate portion 210 and the heat source 204. Although in other embodiments, the liner may only surround a portion of the length of the substrate portion 210, in some embodiments the liner may substantially surround the entire substrate portion 210. In some embodiments, the outer wrapper material 202 may include an inner liner. Thus, in some embodiments, the outer wrapper material 202 and the inner liner may be separate materials provided together (e.g., bonded, fused or otherwise coupled together as a laminate). In other embodiments, the outer wrapper 202 and the inner liner may be the same material. In any case, the inner liner may be configured to thermally regulate the heat generated by the ignited heat source 204 to be conducted radially outwardly in the inner liner. Therefore, in some embodiments, the substrate may be composed of a metal foil material, an alloy material, a ceramic material, or other thermally conductive amorphous carbon-based material and / or an aluminum material, and may include a laminate in some embodiments. In some embodiments, depending on the materials of the outer wrap 202 and / or the inner liner, a thin insulating / insulating layer may be provided radially outward of the inner liner. Thus, in some aspects, the inner liner may advantageously provide a means of joining two or more separate components of the aerosol generating component 200 (e.g., a portion of the heat source 204, the substrate portion 210, and / or the mouthpiece portion 214) while also providing a means of promoting heat transfer along its axial direction but limiting heat conduction radially outward.

[0255] like Figure 5 As shown, the outer wrapper 202 (and the liner and substrate portion 210, if necessary) may also include one or more openings formed therethrough that allow air to enter when drawing on the mouthpiece portion 214. In various embodiments, the size and number of these openings may vary according to specific design requirements. In the illustrated embodiment, a plurality of openings 220 are located near the end of the substrate portion 210 closest to the heat source 204, and a plurality of separate cooling openings 221 may be formed in the outer wrapper material 202 in the region of the filter portion 212 near the mouthpiece portion 214. Although other embodiments may be different, in the illustrated embodiment, the openings 220 include a plurality of openings substantially evenly spaced around the outer surface of the aerosol generating component 200, and the openings 221 also include a plurality of openings substantially evenly spaced around the outer surface of the aerosol generating component 200. Although in various embodiments, a plurality of openings may be formed in a variety of ways through the outer wrapper material 202 (in some embodiments, through the liner), in the illustrated embodiment, the plurality of openings 220 and the plurality of separate cooling openings 221 are formed by laser perforation.

[0256] Return to reference Figure 6, the aerosol generating component 200 of the illustrated embodiment also includes an intermediate component 208 and at least one filter portion 212. It should be noted that in various embodiments, the intermediate component 208 or the filter portion 212 (alone or together) can be considered as the mouthpiece portion 214 of the aerosol generating component 200. Although in various embodiments, neither the intermediate component nor the filter portion is required to be included, in the illustrated embodiment, the intermediate component 208 includes a substantially rigid member that is substantially inflexible along its longitudinal axis. In the illustrated embodiment, the intermediate component 208 includes a hollow tube structure, and including the hollow tube structure increases structural integrity for the aerosol generating component 200 and provides cooling for the generated aerosol. In some embodiments, the intermediate component 208 can be used as a container for collecting aerosols. In various embodiments, the component can be constructed of any variety of materials and can include one or more adhesives. Exemplary materials include, but are not limited to, paper, paper layers, cardboard, plastic, cardboard, and / or composite materials. In the illustrated embodiment, the intermediate component 208 includes a hollow cylindrical element constructed of paper or a plastic material (e.g., ethyl vinyl acetate (EVA), or other polymer materials (e.g., polyethylene, polyester, silicone, etc.), or ceramics (e.g., silicon carbide, aluminum oxide, etc.), or other acetate fibers), and the filter portion includes a filling rod or cylindrical disc constructed of a breathable material (e.g., cellulose acetate or fibers, such as paper or rayon, or polyester fibers).

[0257] As previously described, in some embodiments, the mouthpiece portion 214 may include a filter portion 212 configured to receive an aerosol therefrom in response to a suction applied to the mouthpiece portion 214. In various embodiments, a filter portion 212 is provided, which in some aspects is provided as a disc disposed radially and / or longitudinally near the second end of the intermediate component 208. In this manner, when suction is drawn on the mouthpiece portion 214, the filter portion 212 receives an aerosol flowing through the intermediate component 208 of the aerosol generating component 200. In some embodiments, the filter portion 212 may include discrete segments. For example, some embodiments may include segments that provide filtration, segments that provide a suction resistance, hollow segments that provide cooling space for the aerosol, segments that provide increased structural integrity, other filter portion segments, and any one or any combination of the above. In some embodiments, the filter portion 212 may additionally or alternatively include strands of tobacco-containing material, such as described, for example, in US Pat. No. 5,025,814 to Raker et al., which is incorporated herein by reference in its entirety.

[0258] In various embodiments, the size and shape of the intermediate component 208 and / or the filter portion 212 can vary, for example, the length of the intermediate component 208 can be about 10 mm to about 30 mm, the diameter of the intermediate component 208 can be about 3 mm to about 8 mm, the length of the filter portion 212 can be about 10 mm to approximately 20 mm, and the diameter of the filter portion 212 can be about 3 mm to approximately 8 mm. In the illustrated embodiment, the intermediate component 208 has a length of about 20 mm and a diameter of about 4.8 mm (and in some embodiments, about 7 mm), and the filter portion 212 has a length of about 15 mm and a diameter of approximately 4.8 mm (or in some embodiments, about 7 mm).

[0259] In various embodiments, ignition of the heat source 204 causes aerosol-forming materials associated with the substrate portion 210 to atomize. Preferably, the elements of the substrate portion 210 do not undergo any significant degree of thermal decomposition (e.g., charring, scorching, or burning), and the atomized components are entrained in the air drawn through the aerosol generating component 200 (including the filter portion 212) and into the user's mouth. In various embodiments, the mouthpiece portion 214 (e.g., the intermediate component 208 and / or the filter portion 212) is configured to receive the generated aerosol therefrom in response to the user applying suction to the mouthpiece portion 214. In some embodiments, the mouthpiece portion can be fixedly joined to the substrate portion 210. For example, an adhesive, a bond, a weld, etc. can be suitable for fixedly joining the mouthpiece portion 214 to the substrate portion 210. In one example, the mouthpiece portion 214 is ultrasonically welded and sealed to the end of the substrate portion 210.

[0260] By reading the above description and the accompanying drawings, a person skilled in the art of the present disclosure may think of many improvements and other embodiments of the present disclosure. Therefore, it should be understood that the present disclosure is not limited to the specific embodiments disclosed herein, and various improvements and other embodiments are also intended to be included within the scope defined by the appended claims. Although specific terms are used herein, these terms are only used in a general and descriptive sense and are not intended to limit the present invention.

[0261] Example

[0262] Various aspects of the present invention can be more fully described through the following embodiments, which are described to illustrate certain aspects of the present invention and should not be regarded as limiting the present invention.

[0263] Example 1: Preparation of heat-not-burn (HNB) aerosol precursor substrate using paper technology

[0264] Aerosol Precursor Substrate 1A (Control Substrate)

[0265] Tobacco (leaf and stem, 400 pounds) is mixed with 10 times of its weight of water, and extracted 1 hour at 70 ℃ in a reverse extractor. The extractor contents are separated into a dilute tobacco extract (3-4% weight / volume (w / v)) and an insoluble tobacco solid portion by centrifugation subsequently. The dilute extract is transferred to a vacuum evaporator and concentrated to 23% solid (w / v). Glycerine (75 pounds) is added, and the mixture is fully mixed to obtain a final liquid composition. Pre-refined wood pulp (25 pounds) is mixed with tobacco solids, and enough water is added to make the mixture reach 1% solid (w / v). The total batch weight is 500 pounds (lbs). A disc refiner is used to refine the wood pulp-tobacco solid mixture, to obtain fibrillated tobacco slurry. The fibrillated tobacco slurry is transported in the head box, and drained on a Fourdrinier paper machine to obtain a wet web or substrate. The substrate is dried to a moisture content of 40-55%. The final liquid composition was added back onto the wet web (spray method) and the wet web was dried to a moisture content of 8-10% (w / w).The resulting sheet was then cut into small leaflets.

[0266] Aerosol Precursor Substrates 1Bi and 1Bii (Substrates of the Invention)

[0267] Aerosol precursor substrate 1Bi was prepared similar to substrate 1A, except that the wood pulp was removed and the glycerol was replaced with a 75 / 25 weight mixture of glycerol and 1,2-propylene glycol. For aerosol precursor substrate 1Bii, calcium carbonate (present as a filler and drainage aid) was mixed with half of the fibrillated tobacco slurry before forming the wet web. The total batch weight was 300 pounds (150 pounds of each substrate).

[0268] Aerosol precursor substrate 1C (substrate of the present invention)

[0269] Aerosol precursor substrate 1C was prepared similarly to substrate 1A, except that the glycerin was replaced with a 50 / 50 weight mixture of glycerin and 1,2-propylene glycol. The total batch weight was 300 pounds (lbs).

[0270] Aerosol precursor substrate 1D (substrate of the present invention)

[0271] Aerosol precursor substrate ID was prepared similar to substrate 1A, except that glycerin was replaced with a 25 / 75 weight mixture of glycerin and 1,2-propylene glycol. The total batch weight was 300 pounds (lbs). See Table 1.

[0272] Aerosol Precursor Substrate 1E (Control Substrate)

[0273] Aerosol precursor substrate IE was prepared similarly to substrate 1B, except that 1,2-propylene glycol was used instead of glycerol. The total batch weight was 300 pounds (lbs). See Table 1.

[0274] Table 1. Formulation of Paper Craft HNB Aerosol Precursor Substrate__

[0275]

[0276] Example 2: Preparation of Cast Sheets of HNB Aerosol Precursor Substrates

[0277] Aerosol Precursor Substrate 2A (Control Substrate)

[0278] Sodium alginate (50 pounds) is slowly added to water (1650 pounds) and hydrated in a high shear mixing tank under vacuum for 30 minutes. In a separate mixing tank, calcium carbonate (250 pounds) is slowly added to glycerol (100 pounds) and tobacco extract powder (100 pounds), and then gently mixed for 30 minutes to form a slurry. The hydrated alginate is then mixed with pre-refined wood pulp of zero freeness, then transferred to the calcium carbonate slurry, and then mixed for another 30 minutes at a medium mixing speed and vacuum to obtain the final slurry. The final slurry is then cast onto a 22-inch wide stainless steel conveyor belt using a casting knife set at a 1-3mm gap opening. Subsequently, the cast material or film is dried into a flat sheet by conveying the film through a 200-foot convection tunnel dryer including multiple heating zones (80-100°C). The total batch weight is 500 pounds. The flat sheet is wound on a bobbin and vacuum-sealed in a polyethylene bag to prevent moisture absorption and clogging during transportation. The spool is then unwound and the sheet is cut into strips (25-20 cuts per square inch).

[0279] Aerosol precursor substrate 2B (substrate of the present invention)

[0280] Aerosol precursor substrate 2B was prepared similar to substrate 2A, except that a 75 / 25 weight mixture of glycerol and 1,2-propylene glycol was used instead of glycerol, and zero freeness pre-refined wood pulp was added to the hydrated alginate and mixed for 30 minutes before being added to the calcium carbonate slurry. The total batch weight was 500 lbs. (See Table 2).

[0281] Aerosol precursor substrate 2C (substrate of the present invention)

[0282] Aerosol precursor substrate 2C was prepared similar to substrate 2A, except that the glycerin was replaced with a 50 / 50 weight mixture of glycerin and 1,2-propylene glycol. The total batch weight was 300 pounds.

[0283] Aerosol precursor substrate 2D (substrate of the present invention)

[0284] Aerosol precursor substrate 2D was prepared similar to substrate 2A, except that the glycerin was replaced with a 25 / 75 weight mixture of glycerin and 1,2-propylene glycol. The total batch weight was 300 pounds.

[0285] Aerosol Precursor Substrate 2E (Control Substrate)

[0286] Aerosol precursor substrate 2E was prepared similarly to substrate 2A, except that 1,2-propylene glycol was used instead of glycerol. The total batch weight was 300 pounds.

[0287] Aerosol Precursor Substrate 2F (Control Substrate)

[0288] Aerosol precursor substrate 2F was prepared similarly to substrate 2A, except that ammonium alginate was used as the binder instead of sodium alginate.

[0289] Table 2. Formulation of Cast Sheet HNB Aerosol Precursor Substrate

[0290]

[0291] Example 3: Preparation of bead and granular rod HNB aerosol precursor substrate

[0292] Aerosol Precursor Substrate 3A (Control Substrate)

[0293] The calcium carbonate (35 pounds) and pregelatinized rice starch (5 pounds) of measurement are added in the FM 130D Littleford type precision plow mixer.Content was mixed 10 minutes under 100rpm (rev / min), glycerine (20 pounds) was added subsequently and further mixed 10 minutes at 100rpm.Stop mixer, and add prefabricated carboxymethyl cellulose slurry (CMC) (it is prepared by using pitchfork propeller (pitched fork propeller) in container with water (17 pounds) hydrated carboxymethyl cellulose (5 pounds) 30 minutes), then further mixed 20 minutes at 100rpm.The contents of plow mixer are distributed and transferred to MG-55-1 type Fuji Paudel multi-granular extruder.This material is extruded by the sieve die (doomed screendie) of 2-3mm, obtains the rod of multi-granular (hair-like) shape.Subsequently, rod is transferred to the Fuji Paudal laboratory spherical granulator that model is QJ-230T-2. The rods were reshaped into round or spherical beads using a spheronizer rotating bowl. The beads were then transferred to a fluidized bed agglomerator (Flo-Coater, Vector Corporation) and finally dried to 10% moisture with heated air at 60-70°C. Some extruded rods were also transferred and subsequently dried using a fluidized bed agglomerator. The total batch weight was 50 pounds.

[0294] Aerosol precursor substrate 3B (substrate of the present invention)

[0295] Aerosol precursor substrate 3B was prepared similar to substrate 3A, except that the glycerin was replaced with a 75 / 25 weight mixture of glycerin and 1,2-propylene glycol. The total batch weight was 50 lbs. See Table 3.

[0296] Aerosol precursor substrate 3C (substrate of the present invention)

[0297] Aerosol precursor substrate 3C was prepared similar to substrate 3A, except that the glycerin was replaced with a 50 / 50 weight mixture of glycerin and 1,2-propylene glycol. The total batch weight was 50 pounds.

[0298] Aerosol precursor substrate 3D (substrate of the present invention)

[0299] Aerosol precursor substrate 3D was prepared similar to substrate 3A, except that the glycerol / 1,2-propylene glycol ratio was a 25 / 75 weight mixture. The total batch weight was 50 pounds.

[0300] Aerosol Precursor Substrate 3E (Control Substrate)

[0301] Aerosol precursor substrate 3E was prepared similarly to substrate 3A, except that 1,2-propylene glycol was used instead of glycerol. The total batch weight was 50 pounds. See Table 3.

[0302] Aerosol Precursor Substrate 3F (Control Substrate)

[0303] Aerosol precursor substrate 3F was prepared similarly to substrate 3A, except that the rice starch was replaced with more ground tobacco. The total batch weight was 50 pounds.

[0304] Table 3. Formulation of Bead and Granular Rod HNB Aerosol Precursor Substrate

[0305]

[0306] Example 4: Preparation of Extruded HNB Aerosol Precursor Substrate

[0307] Aerosol Precursor Substrate 4A (Control Substrate)

[0308] Hydroxypropyl methylcellulose (HPMC; 2.5 pounds) and hydroxypropyl cellulose (HPC; 2.5 pounds) were mixed with glycerol (25 pounds) in a Hobart mixer for 20 minutes. The mixture was then added to calcium carbonate (10 pounds), pregelatinized rice starch (30 pounds) and tobacco powder (30 pounds) in a FM 130D Littleford precision plow mixer and mixed at 100 rpm for 30 minutes. After 30 minutes, the plow mixer contents were transferred to a K-Tron hopper connected to a model ZSK-25 Coperion twin-screw extruder. The hopper contents were then fed to the extruder, which included 11 barrel sections (27-100° C.) running at a screw speed of 75 rpm. Water (35 pounds) was fed into the second barrel of the extruder to facilitate kneading, mixing and plasticization of the dough. A variety of extrudate shapes were produced using forming dies (flat sheets, solid rods, rods with central or internal holes, rods with grooved outer edges). Except for the flat sheet extrudates, the resulting extrudates were cut upon exiting the die and immediately dried to 10-12% moisture using an infrared tunnel dryer (Model Proj 0115 Glenroe Integrated Energy Delivery System). The total batch weight was 100 pounds.

[0309] Aerosol Precursor Substrate 4B (Substrate of the Present Invention)

[0310] Aerosol precursor substrate 4B was prepared similar to substrate 4A, except that the glycerin was replaced with a 50 / 50 weight mixture of glycerin and 1,2-propylene glycol. The total batch weight was 50 pounds.

[0311] Aerosol Precursor Substrate 4C (Substrate of the Present Invention)

[0312] Aerosol precursor substrate 4C was prepared similar to substrate 4A, except that the glycerol / 1,2-propylene glycol ratio was a 25 / 75 weight ratio mixture, the amount of rice starch, HPMC and HPC was reduced, and liquid mint flavor was added to the glycerol / propylene glycol mixture to impart flavor to the formulation. The total batch weight was 50 pounds.

[0313] Table 4. Formulation of Extruded HNB Aerosol Precursor Substrate

[0314]

[0315] Example 5. DSC of aerosol-forming materials

[0316] Several embodiments of liquid aerosol-forming materials and mixtures containing glycerol or 1,2-propylene glycol (control) and mixtures thereof in different ratios (invention) were prepared. The thermal profiles of these embodiments were measured by differential scanning calorimetry (DSC). DSC measures the energy absorbed (enthalpy) or the amount of heat required (heat of evaporation) and the energy released (exotherm) when the aerosol precursor changes phase (liquid to vapor) during heating. The results of these experiments (Tables 5 and Figure 7 ) showed that when 1,2-propylene glycol (PG) was mixed with glycerol (VG) at levels >50%, less heat or energy (endothermic) was required to change the aerosol-forming material from liquid to aerosol. The latter suggests that combining aerosol precursors with different boiling points or vapor pressures can form aerosols over a wider temperature range than the individual parts.

[0317] Table 5. DSC of aerosol forming materials

[0318]

[0319] Example 6. DSC of aerosol generating components

[0320] The thermal distribution of the embodiment of the aerosol generating component within the substrate matrix is ​​measured by DSC. In the examples evaluated, similar trends of reduced endothermic / enthalpy as the PG inclusion in the liquid mixture increases were observed (Table 6). In general, in any matrix (paper regeneration, cast sheet or beaded product), the higher the ratio of PG to glycerol (>50%), the lower the enthalpy of evaporation or heat of evaporation. The data in Table 6 also show that aerosol formation is affected by the form of the matrix, such as the lower enthalpy of the beaded product.

[0321] Table 6. DSC of aerosol generating components

[0322]

[0323] a Endotherm - Energy absorbed or required to change phases of recrystallization and aerosol precursors.

[0324] b Exotherm - The energy released after recombination and aerosol phase change equilibrium.

[0325] Example 7. Thermogravimetric analysis mass spectrometry (TGA / MS) ion curve of aerosol generating components in a substrate matrix

[0326] The ion profile of an embodiment of the aerosol generating component within the substrate matrix was measured by TGA / MS.The substrate sample was heated from ambient temperature to 250°C (1 minute) and then held at 250°C for 4 minutes. Figure 8 (Overlay of glycerol ion current curves (M / Z 43); paper reconstruction process substrate) and Fig. 9 (Overlay of glycerol ion current curves (M / Z 43); bead substrate) shows that the mixed glycerol-PG sample has a broader distribution of aerosolized glycerol ion curves over time compared to the glycerol or PG-only counterparts. These findings demonstrate the advantages of using a mixture of two or more aerosol-forming materials to form an aerosol over a period of time, relative to forming an aerosol with one aerosol-forming material.

[0327] Example 8. Thermogravimetric analysis of aerosol-forming materials

[0328] The weight change of nine samples of aerosol-forming materials when heated from room temperature to 260°C was studied using thermogravimetric analysis (TGA). Each sample weighed approximately 5-10 mg for TGA application. TGA testing was performed on a TA Instruments TGA 5500. The method used in this study applied a temperature ramp program of 500°C / min to 210°C and then to 260°C to most efficiently raise the temperature to 260°C without overshoot. The heating program allowed the sample to heat from room temperature to 260°C in one minute and then remain under isothermal conditions for an additional 4 minutes. The weight change was monitored between 0 and 1 minute and between 1 and 5 minutes. Three equal portions of the sample were tested. The average weight loss of the three equal portions was calculated and is provided in Table 7. The temperature of the sample at 1 minute and 5 minutes is also reported in Table 7.

[0329] As shown, many of the materials tested resist volatilization during the first minute of heating, as shown by the relatively low weight loss in the first minute. Specifically, glycerol, palmitic acid, PEG400, sorbitan tristearate, and polysorbate 80 all exhibited less than 50% weight loss in the first minute. This suggests that these compounds are useful in a mixture with another aerosol-forming material that evaporates faster. Differently, 1,3-propylene glycol, triethylene glycol, 1,2-propylene glycol, and triacetin all exhibit significantly higher volatility in the first minute. Therefore, these compounds can be good candidates for mixing with the above-mentioned less volatile compounds. Such a combination can produce consistent aerosol volumes over a series of puffs, and the more volatile aerosol-forming compounds account for a larger percentage in the early puffs, while the less volatile compounds account for a larger percentage in the later puffs.

[0330] Furthermore, for the PEG400, sorbitan tristearate, and polysorbate 80 samples, less than 50% of the samples were aerosolized after 5 minutes, indicating that these compounds may be well suited for aerosol devices operating at higher temperatures (eg, about 280-300°C).

[0331] Table 7: Average sample weight loss and temperature at each time point of the aerosol formation sample

[0332]

[0333] Example 9. Thermogravimetric analysis mass spectrometry (TGA / MS) of aerosol-forming material mixtures

[0334] Using TGA-MS, the release profiles of eight aerosol-forming material mixture samples according to Table 8 were studied. All tests were performed on a TA Instrument Discovery TGA 5500 instrument connected to a Discovery mass spectrometer. All experiments were performed in high purity nitrogen. Tests were performed in duplicate for confirmation purposes.

[0335] Each sample contained two aerosol forming materials shown in Table 8 in a weight ratio of 1:1. About 2-4 mg of each sample was weighed in a peeled aluminum pan for analysis. The sample was heated to 210°C using a 50°C / minute heating program and then to 260°C. The heating program allowed the sample to heat from room temperature to 260°C in one minute and then to remain at isothermal conditions for another 4 minutes. The ion fragments of each sample are listed in Table 8 (according to the MS spectrum reference of the National Institute of Standards and Technology of the United States), and each mixture sample was monitored using the settings of Faraday 7 in the peak jump recipe of the mass spectrometer.

[0336] Table 8. Sample (mixture in 50 / 50 ratio) and illustrated fragment M / Z of ions monitored

[0337] Sample No. Aerosol forming materials M / Z 1 Glycerin / 1,2-Propylene glycol 43 / 45 2 Glycerol / Triacetin 43 / 103,145 3 Glycerin / Triethylene glycol 43 / 58,89 4 Glycerin / 1,3-Propanediol 43 / 57,58 5 Palmitic acid / 1,2-propylene glycol 41,57 / 45 6 Palmitic acid / triacetin 41,57 / 103,145 7 Palmitic acid / triethylene glycol 41,57 / 58,89 8 Palmitic acid / 1,3-propylene glycol 41,57 / 57,58

[0338] Fig.10 The TGA thermograms of all eight samples are provided in , from which it can be observed that the mixture containing glycerol lost all weight before 0.75 minutes, and the mixture containing palmitic acid continued to lose some weight after 0.75 minutes. It was also observed from the TGA curves that all the samples tested evaporated within one minute.

[0339] The ion currents of the eight samples were smoothed in Trios software using a setting of 15. It was observed that most of the mixture samples that formed aerosols precipitated at about 1 minute or less, except for the mixtures of glycerol / 1,2-propylene glycol, glycerol / triethylene glycol, and glycerol / 1,3-propylene glycol. These three mixture samples could be detected in about two minutes. From the earlier TGA weight loss results, all weight losses were completed within one minute.

[0340] The above data demonstrate that aerosol-forming material mixtures comprising palmitic acid can be used to provide a more consistent aerosol volume delivery over time, resulting in less puff-to-puff variability in smoking articles comprising such mixtures.

[0341] Example 10. Thermogravimetric analysis mass spectrometry (TGA / MS) ion curve of aerosol generating material in substrate matrix

[0342] Ten samples of handsheet substrate containing various aerosol precursor mixtures were prepared according to the recipes provided in Table 9. The aerosol-forming materials in each sample are provided in Table 10.

[0343] Table 9. Handmade sheet substrate sample composition

[0344] composition Percentage by dry weight Milled tobacco 60 Wood pulp 7.5 Carboxymethyl cellulose 2500 12.5 Aerosol forming materials 20

[0345] The release profiles of ten handmade sheet samples were studied using TGA-MS. All tests were performed on a TA Instrument Discovery TGA 5500 instrument connected to a Discovery mass spectrometer. All experiments were performed in high purity nitrogen. Tests were performed in duplicate for confirmation purposes.

[0346] About 2-4 mg of each sample was weighed in a peeled aluminum pan for analysis. The sample was heated to 210°C using a 50°C / min heating program and then to 260°C. The heating program allowed the sample to heat from room temperature to 260°C in one minute and then to remain at isothermal conditions for another 4 minutes. The ion fragments of each sample are listed in Table 10 (based on the MS spectrum reference of the National Institute of Standards and Technology) and each mixture sample was monitored using the settings of Faraday 7 in the peak jump recipe of the mass spectrometer.

[0347] Table 10. Substrate samples containing aerosol forming materials and ion fragmentation M / Z monitoring

[0348] Sample No. Aerosol-forming materials (% by respective dry weight) M / Z A Palmitic acid / 1,3-propylene glycol (10 / 10) 41,57 / 57,58 B Palmitic acid / triethylene glycol (10 / 10) 41,57 / 58,89 C Palmitic acid / triacetin (10 / 10) 41,57 / 103,145 D Palmitic acid / 1,2-propylene glycol (10 / 10) 41,57 / 45 E Glycerin / 1,2-propylene glycol (10 / 10) 43 / 45 F Palmitic acid (20) 41 G Palmitic acid / 1,3-propylene glycol (15 / 5) 41,57 / 57,58 H Palmitic acid / 1,3-propylene glycol (10 / 10) 41,57 / 57,58 I Palmitic acid / 1,3-propylene glycol (5 / 15) 41,57 / 57,58 J 1,3-Propanediol (20) 57 / 57,58

[0349] Fig.11 An overlay of the TGA thermograms of all 10 samples is shown. From the TGA overlay curves, it can be observed that the samples lose most of the volatile portion within 1 minute.

[0350] Regarding mass spectrometry analysis, no ion current signals were observed for test samples A, B, C, F, I, and J, and only small signals were observed for samples D, E, G, and H. The absence or small signals of the alternative aerosol precursor samples may be due to the loss of aerosol-forming materials during the drying process during the manual sheet sample preparation or before the sample testing. As shown in Table 10, the aerosol lifetimes of samples D, E, G, and F are longer than those of the other candidate samples.

[0351] Example 11. Thermogravimetric analysis mass spectrometry (TGA / MS) ion curve of aerosol generating material in substrate matrix

[0352] Eight handsheet substrate samples containing various aerosol precursor mixtures were prepared in matrix form according to the recipes provided in Table 11, all weight percentages are on a dry basis.

[0353] Carboxymethyl cellulose (CMC2500) is slowly added to water and hydrated in a high shear mixing tank under vacuum for 30 minutes. In a separate mixing tank, finely ground tobacco is slowly added to aerosol-forming materials and water, and then gently mixed for 30 minutes to form a slurry of tobacco and water. The hydrated CMC2500 is then mixed with a pre-refined wood pulp of zero freeness, and then transferred to a slurry tank of tobacco and water, and then mixed for another 30 minutes at a medium mixing speed and vacuum to obtain a final slurry.

[0354] The final slurry was then cast onto a 22 inch wide stainless steel conveyor belt using a casting knife set at a 1-3 mm gap opening. The cast material (film) was then dried into a flat sheet by conveying the film through a 200 foot convection tunnel dryer that included multiple heating zones (80-100° C.). The flat sheet was wound onto a bobbin and vacuum sealed in a polyethylene bag to prevent moisture absorption and clogging during transportation. The bobbin was then unwound and the sheet was cut into strips (25-20 cuts per square inch).

[0355] The release profiles of eight handsheet samples were studied according to the procedure in Example 10.

[0356] Table 11. Handmade sheet substrate sample components

[0357]

[0358] Example 12. Thermogravimetric analysis of aerosol generating material combinations

[0359] A set of 16 aerosol forming material combinations were prepared and studied by TGA using the procedure of Example 9. The matrix is ​​provided in Table 12. Each identified aerosol forming material was present in a binary mixture in a 1:1 weight ratio. The release profiles of the 16 samples were studied according to the procedure in Example 8.

[0360] Table 12. Sample description in matrix form

[0361]

[0362] Example 13. Thermogravimetric analysis of aerosol generating materials in a substrate matrix

[0363] Six samples of hand sheet substrates containing various aerosol precursor mixtures were prepared according to the recipes provided in Table 9. The aerosol-forming materials in each sample are provided in Table 13, and all weight percentages are dry weights. The release profiles of the six hand sheet samples were studied using TGA. All tests were performed on a TA Instrument Discovery TGA 5500 instrument. The tests were performed in three replicates for confirmation purposes. The weight loss average of the three replicates was calculated and is provided in Table 13.

[0364] About 3-5 mg of each sample was weighed in a tared aluminum pan for analysis. The sample was heated to 210°C using a 500°C / min temperature ramp and then to 260°C. The heating program allowed the sample to heat from room temperature to 260°C in one minute and then to remain at isothermal conditions for another 4 minutes. The weight change was monitored from 0 to 5 minutes.

[0365] Results show that most of the weight loss occurred within the first minute during the rapid heating process. The most weight loss occurred in the first minute in control sample 17A (glycerol; 35.4%), while the least weight loss occurred in sample 41A (glycerol palmitic acid; 27.8%). This data particularly supports that the combination of glycerol with palmitic acid, triethylene glycol, or triacetin provides a more sustained aerosol release from the substrate over time, which may help provide less puff variation. In contrast, the combination of glycerol with 1,3-propanediol or glycerol with 1,2-propylene glycol was virtually indistinguishable from the glycerol control.

[0366] Table 13. Composition of hand sheet substrate samples and average weight loss and temperature at each time point

[0367]

[0368] Example 14: Preparation of Cast Sheets of HNB Aerosol Precursor Substrates

[0369] A series of six substrates containing various aerosol-forming materials were prepared using the components and amounts shown in Table 14.

[0370] Aerosol Precursor Substrate 14A (Control Substrate)

[0371] Carboxymethyl cellulose (CMC2500; 2.5 pounds) was slowly added to water (100 pounds) and hydrated in a high shear mixing tank under vacuum for 30 minutes. In a separate mixing tank, finely ground tobacco (12 pounds) was slowly added to glycerol (4 pounds) and water (5 pounds), and then gently mixed for 30 minutes to form a slurry of tobacco and water. The hydrated CMC2500 was then mixed with a pre-refined wood pulp of zero freeness, then transferred to a slurry tank of tobacco and water, and then mixed for another 30 minutes at a medium mixing speed and vacuum to obtain a final slurry. The final slurry was then cast onto a 22-inch wide stainless steel conveyor belt using a casting knife set at a 1-3mm gap opening. Subsequently, the cast material (film) was dried into a flat sheet by conveying the film through a 200-foot convection tunnel dryer including multiple heating zones (80-100°C). The total dry weight of the batch was 20 pounds. The flat sheet is wound onto a spool and vacuum sealed in a polyethylene bag to prevent moisture absorption and clogging during shipping. The spool is then unwound and the sheet is cut into strips (25-20 cuts per square inch).

[0372] Aerosol Precursor Substrate 14B

[0373] Aerosol precursor substrate 14B was prepared similarly to substrate 14A, except that the glycerol was replaced with a 1 / 1 weight mixture of glycerol and palmitic acid. The total batch weight was 20 pounds.

[0374] Aerosol Precursor Substrate 14C

[0375] Aerosol precursor substrate 14C was prepared similarly to substrate 14A, except that the glycerin was replaced with a 1 / 1 weight mixture of glycerin and triethylene glycol. The total batch weight was 20 pounds.

[0376] Aerosol Precursor Substrate 14D

[0377] Aerosol precursor substrate 14D was prepared similarly to substrate 14A, except that the glycerol was replaced with a 1 / 1 weight mixture of glycerol and triacetin. The total batch weight was 20 pounds.

[0378] Aerosol Precursor Substrate 14E (Control)

[0379] Aerosol precursor substrate 14E was prepared similar to substrate 14A, except that glycerol was replaced with a mixture of glycerol and 1,2-propylene glycol (1:1 weight ratio). The total batch weight was 20 pounds.

[0380] Aerosol Precursor Substrate 14F

[0381] Aerosol precursor substrate 14F was prepared similar to substrate 14A except that the glycerol was replaced with a 1:1.5:1.5 weight mixture of glycerol, palmitic acid, and 1,3-propylene glycol. The total batch weight was 20 pounds.

[0382] Table 14. Formulation of Cast Sheet HNB Aerosol Precursor Substrate

[0383]

Claims

1. An aerosol generating component comprising a substrate impregnated with two or more aerosol forming materials, comprising: a first aerosol-forming material selected from the group consisting of glycerol, 1,2-propylene glycol, 1,3-propylene glycol, diethylene glycol, triethylene glycol, polyethylene glycol, glyceryl triacetate, and combinations thereof; and a second aerosol-forming material that is different from the first aerosol-forming material and is selected from the group consisting of polysorbates, sorbitan esters, fatty acids, fatty acid esters, 1,3-propylene glycol, triethylene glycol, polyethylene glycol, triacetin, waxes, terpenes, and sugar alcohols; wherein the first aerosol-forming material and the second aerosol-forming material each have a different boiling point, a different vapor pressure, or a different boiling point and a different vapor pressure; and Therein, the substrate is impregnated with the two or more aerosol-forming materials at a loading of about 5 wt % to about 60 wt %, based on the total weight of the impregnated substrate.

2. The aerosol generating component according to claim 1, wherein: The substrate is impregnated with the two or more aerosol-forming materials at a loading of about 15 wt % to about 30 wt %, based on the total weight of the impregnated substrate.

3. The aerosol generating component according to claim 1 or 2, wherein: The weight ratio of the first aerosol-forming material to the second aerosol-forming material is from about 100:1 to about 1:

100.

4. The aerosol generating component according to any one of claims 1 to 3, wherein: The weight ratio of the first aerosol-forming material to the second aerosol-forming material is from about 3:1 to about 1:

3.

5. The aerosol generating component according to any one of claims 1 to 4, wherein: The second aerosol-forming material is selected from the group consisting of palmitic acid, polyethylene glycol 400, sorbitan tristearate, polysorbate 80, and combinations thereof.

6. The aerosol generating component according to any one of claims 1 to 4, wherein: The first aerosol-forming material is glycerol, and the second aerosol-forming material is 1,3-propylene glycol, triethylene glycol, palmitic acid or glyceryl triacetate.

7. The aerosol generating component according to any one of claims 1 to 4, wherein: The first aerosol-forming material is glycerol and the second aerosol-forming material is palmitic acid.

8. The aerosol generating component according to any one of claims 1 to 4, wherein: The first aerosol-forming material is 1,3-propylene glycol, triethylene glycol, 1,2-propylene glycol, or triacetin; and The second aerosol-forming material is palmitic acid, polyethylene glycol 400, sorbitan tristearate or polysorbate 80.

9. The aerosol generating component according to any one of claims 1 to 4, wherein: The substrate is impregnated with glycerol, palmitic acid and a third aerosol-forming material selected from the group consisting of 1,3-propylene glycol, triethylene glycol, 1,2-propylene glycol, glyceryl triacetate, polyethylene glycol 400, sorbitan tristearate and polysorbate 80.

10. The aerosol generating component according to any one of claims 1 to 4, wherein: The substrate is impregnated with a mixture selected from the group consisting of: Glycerol and palmitic acid; Glycerin and 1,3-propylene glycol; Glycerin and triethylene glycol; glycerol and triacetin; 1,3-Propanediol and palmitic acid; 1,3-Propanediol and polyethylene glycol; 1,3-Propanediol and polysorbate 80; triethylene glycol and palmitic acid; triethylene glycol and polyethylene glycol; triethylene glycol and polysorbate 80; triacetin and palmitic acid; triacetin and polyethylene glycol; triacetin and polysorbate 80; 1,2-Propanediol and palmitic acid; 1,2-Propanediol and polyethylene glycol; and 1,2-Propanediol and polysorbate 80.

11. The aerosol generating component according to claim 10, wherein: In each of the listed mixtures, the ratio of aerosol-forming materials is from about 3:1 to about 1:

3.

12. The aerosol generating component according to any one of claims 1 to 4, wherein: The substrate was impregnated with a mixture comprising glycerol, palmitic acid and 1,2-propylene glycol.

13. The aerosol generating component according to claim 12, further comprising triacetin.

14. The aerosol generating component according to any one of claims 1 to 13, wherein: The substrate also comprises up to about 10% by weight water, based on the total dry weight of the impregnated substrate.

15. The aerosol generating component according to any one of claims 1 to 14, wherein: The substrate comprises tobacco-derived fibers, wood-derived fibers, plant or plant-derived fibers, synthetic fibers, or combinations thereof; and one or more binders.

16. The aerosol generating component according to any one of claims 1 to 15, wherein: The one or more binders are selected from alginate, cellulose derivatives, starch, gum, dextran, carrageenan, calcium carbonate or a combination thereof.

17. The aerosol generating component according to any one of claims 1 to 16, wherein: The substrate contains: about 40% to about 70% by weight tobacco-derived fibers; from about 10% to about 15% by weight of a cellulose derivative; and From about 5% to about 10% by weight wood pulp.

18. The aerosol generating component according to any one of claims 1 to 17, wherein: The substrate is further impregnated with a fragrance, an active ingredient, or a combination thereof.

19. The aerosol generating component according to claim 18, wherein: The active ingredients include tobacco components, non-tobacco botanicals, nicotine components, or combinations thereof.

20. The aerosol generating component according to claim 18, wherein: The active ingredients include a nicotine component.

21. The aerosol generating component according to any one of claims 1 to 20, wherein: The substrate is in the form of particles, cut strands, films, paper processed sheets, cast sheets, beads, granules, rods or extrudates.

22. The aerosol generating component according to claim 21, wherein: The substrate is formed into a substantially cylindrical shape.

23. An aerosol delivery device comprising: An aerosol generating component according to any one of claims 1 to 22; a heat source configured to heat the impregnated substrate to form an aerosol; and An aerosol path extends from the aerosol generating component to the mouthpiece end of the aerosol delivery device.

24. An aerosol delivery device according to claim 23, wherein: Heat sources include electrically powered heat generating elements or combustible ignition sources.

25. An aerosol delivery device according to claim 24, wherein: The heat source is a combustible ignition source comprising a carbon-based material.

26. The aerosol delivery device of claim 24, wherein: The heat source is an electrically powered heating element.

27. An aerosol delivery device according to claim 26, further comprising a power source electrically connected to the heating element.

28. The aerosol delivery device of claim 27, further comprising a controller configured to control power delivered by the power source to the heating element.

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