Substrate having multiple aerosol-forming materials for an aerosol delivery device - Patent Application 20070123633

Abstract

The present disclosure provides an aerosol generating member comprising a substrate impregnated with two or more aerosol forming materials, including a first aerosol forming material and a second aerosol forming material, each of which has a different boiling point, different vapor pressure, or both. The disclosed aerosol generating member may be utilized in an aerosol delivery device, such as a non-combustion heated (HNB) or electrically heated aerosol delivery device.

Description

[Technical field]

[0001] The present disclosure relates to aerosol generating members, aerosol delivery devices and aerosol delivery systems, such as smoking articles, that utilize electrically generated heat or a combustible ignition source to heat aerosol-forming materials, preferably without significant combustion, to provide an inhalable substance in the form of an aerosol for human consumption. [Background technology]

[0002] Many smoking articles have been proposed over the years as an improvement or replacement for smoking products based on the combustion of tobacco for use. Some alternatives include devices that burn solid or liquid fuels to transfer heat to tobacco or devices that use chemical reactions to provide such a heat source. Additional alternatives use electrical energy to heat tobacco and / or other aerosol-generating substrate materials, as described, for example, in U.S. Patent No. 9,078,473 to Worm et al., which is incorporated herein by reference in its entirety.

[0003] The gist of improvements or replacements to smoking articles has typically been to provide the sensations associated with cigarette, cigar or pipe smoking without delivering significant amounts of incomplete combustion and pyrolysis products.To this end, numerous smoking products, flavor generators and medicinal inhalers have been proposed that utilize electrical energy to vaporize or heat volatile materials or attempt to provide the sensations of cigarette, cigar or pipe smoking without significantly burning tobacco.See, for example, the various alternative smoking articles, aerosol delivery devices and heat sources described in the background art set forth in U.S. Patent No. 7,726,320 to Robinson et al. and U.S. Patent Application Publication No. 2013 / 0255702 to Griffith, Jr. et al. and U.S. Patent Application Publication No. 2014 / 0096781 to Sears et al., each of which is incorporated herein by reference in its entirety.

[0004] Articles that produce the taste and sensation of smoking by electrically heating tobacco, tobacco-derived materials, or other plants or plant-derived materials have suffered from inconsistent performance characteristics.For example, some articles have suffered from inconsistent release of flavor or other inhalation materials and inadequate loading of aerosol-forming materials on the substrate.Therefore, it is desirable to provide a smoking article that has advantageous performance characteristics without burning substrate materials and can provide the sensation of smoking a cigarette, cigar, or pipe.

[0005] Aerosol delivery devices that utilize electrically generated heat as well as aerosol delivery devices that transfer heat to tobacco by burning solid fuel such as carbon have an aerosol-forming substrate as part of the aerosol generating member. Typically, only one aerosol-forming agent is used in the aerosol-forming substrate. Thus, the tendency of aerosol formation when the substrate is heated depends on the boiling point or vapor pressure of the aerosol-forming agent. In both types of devices, it is advantageous to provide a substrate that contains multiple aerosol-forming agents to allow controlled release of aerosol over time when the substrate is heated. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] U.S. Pat. No. 9,078,473 [Patent Document 2] U.S. Patent No. 7,726,320 [Patent Document 3] US Patent Application Publication No. 2013 / 0255702 [Patent Document 4] US Patent Application Publication No. 2014 / 0096781 Summary of the Invention [Means for solving the problem]

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

[0008] Thus, in one aspect, the present disclosure provides an aerosol-generating member comprising a substrate impregnated with two or more aerosol-forming materials including a first aerosol-forming material and a second aerosol-forming material, each of the first aerosol-forming material and the second aerosol-forming material having a different boiling point, different vapor pressure, or both.

[0009] In some embodiments, the first aerosol-forming material and the second aerosol-forming material are independently selected from the group consisting of water, polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, triacetins, and sugar alcohols. In some embodiments, at least one of the first aerosol-forming material and the second aerosol-forming material is a polyhydric alcohol. In some embodiments, the two or more aerosol-forming 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.

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

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

[0012] In some embodiments, the substrate is further impregnated with a flavorant, an active ingredient, or a combination thereof. In some embodiments, the active ingredient comprises a tobacco component, a non-tobacco plant material, a nicotine component, or a combination thereof. In some embodiments, the active ingredient comprises a nicotine component.

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

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

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

[0016] In some embodiments, the substrate further comprises one or more binders. In some embodiments, the one or more binders are selected from alginates, cellulose derivatives, starches, gums, dextran, carrageenans, calcium carbonate, or combinations thereof. In some embodiments, the substrate comprises one or more of calcium carbonate, alginates, one or more cellulose derivatives, starches, 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 propylene glycol.

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

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

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

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

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

[0023] In another aspect, there is provided an aerosol-generating member comprising a substrate impregnated with two or more aerosol-forming materials, the two or more aerosol-forming materials including a first aerosol-forming material selected from the group consisting of glycerol, propylene glycol, 1,3-propanediol, 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-propanediol, triethylene glycol, polyethylene glycol, triacetin, waxes, cannabinoids, terpenes, and sugar alcohols; the first aerosol-forming material and the second aerosol-forming material each have different boiling points, different vapor pressures, or both; and the substrate is impregnated with the two or more aerosol-forming materials at a loading of about 5 to about 60 wt %, based on the total weight of the impregnated substrate.

[0024] In some embodiments, the substrate is impregnated with two or more aerosol-forming materials at a loading of about 15 to about 30% by weight, 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 from 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 from 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-propanediol, triethylene glycol, palmitic acid, or triacetin, hi 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-propanediol, triethylene glycol, 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 a third aerosol-forming material selected from the group consisting of glycerol, palmitic acid, and 1,3-propanediol, triethylene glycol, propylene glycol, triacetin, 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-propanediol; glycerol 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; propylene glycol and palmitic acid; propylene glycol and polyethylene glycol; and propylene glycol and polysorbate 80. In some embodiments, the ratio of aerosol-forming materials in each recited 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 propylene glycol.

[0032] In some embodiments, the aerosol-generating member further comprises triacetin.

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

[0034] In some embodiments, the substrate comprises tobacco-derived fiber, wood-derived fiber, plant or plant-derived fiber, synthetic fiber, 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: about 40 to about 70 weight percent tobacco-derived fiber; about 10 to about 15 weight percent cellulose derivative; and about 5 to about 10 weight percent wood pulp.

[0036] In some embodiments, the substrate is further impregnated with a flavorant, an active ingredient, or a combination thereof. In some embodiments, the active ingredient comprises a tobacco component, a non-tobacco plant material, a nicotine component, or a combination thereof. In some embodiments, the active ingredient comprises a nicotine component.

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

[0038] In another aspect, there is provided an aerosol delivery device comprising an aerosol generating member as described herein; a heat source configured to heat an aerosol forming material impregnated in a substrate portion to form an aerosol; and an aerosol pathway extending from the aerosol generating member to a mouth end of the aerosol delivery device.

[0039] In some embodiments, the heat source comprises either an electric heating 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 electric heating 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 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 member comprising a substrate 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, different vapor pressure, or both.

[0042] Embodiment 2: The aerosol generating member of embodiment 1, wherein the first aerosol forming material and the second aerosol forming material are independently selected from the group consisting of water, polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, triacetin, and sugar alcohols.

[0043] Embodiment 3: The aerosol-generating member according to embodiment 1 or 2, wherein the two or more aerosol-forming 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 member according to any one of embodiments 1 to 3, wherein at least one of the first aerosol-forming material and the second aerosol-forming material is a polyhydric alcohol.

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

[0046] Embodiment 6: The aerosol-generating member according to any one of embodiments 1 to 5, wherein the polyhydric alcohol is selected from the group consisting of glycerol, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, and combinations thereof.

[0047] Embodiment 7: The aerosol-generating member according to any one of embodiments 1 to 6, wherein the polyhydric alcohol is glycerol and propylene glycol.

[0048] Embodiment 8: An aerosol-generating member according to any one of embodiments 1 to 7, wherein the glycerol and propylene glycol are present in a weight ratio of about 3:1 to about 1:3.

[0049] Embodiment 9: An aerosol generating member according to any one of embodiments 1 to 8, wherein the glycerol and propylene glycol are present in a weight ratio of about 1:1.

[0050] Embodiment 10: An aerosol-generating member according to any one of embodiments 1 to 9, wherein the substrate is further impregnated with at least one additional aerosol-forming agent.

[0051] Embodiment 11: An aerosol generating member described in any one of embodiments 1 to 10, wherein at least one additional aerosol forming agent is selected from the group consisting of water, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, triacetin, sugar alcohols, cannabinoids, terpenes, and combinations thereof.

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

[0053] Embodiment 13: An aerosol-generating member according to any one of embodiments 1 to 12, wherein the active ingredient comprises a non-tobacco plant substance, a tobacco component, a nicotine component, or a combination thereof.

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

[0055] Embodiment 15: The aerosol-generating member of any one of embodiments 1 to 14, wherein the substrate is impregnated with two or more aerosol-forming materials at a loading of about 15 to about 55 wt %, based on the total weight of the impregnated substrate.

[0056] Embodiment 16: An aerosol-generating member according to any one of embodiments 1 to 15, wherein the substrate is in particulate form, shredded form, film form, paper process sheet form, cast sheet form, bead form, granular rod form, or extrudate form.

[0057] Embodiment 17: An aerosol-generating member according to any one of embodiments 1 to 16, wherein the substrate is formed in a substantially cylindrical shape.

[0058] Embodiment 18: The aerosol-generating member 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: An aerosol-generating member according to any one of embodiments 1 to 18, wherein the substrate further comprises one or more binders.

[0060] Embodiment 20: An aerosol generating member described in any one of embodiments 1 to 19, wherein the one or more binders are selected from alginates, cellulose derivatives, starches, gums, dextran, carrageenan, calcium carbonate, or combinations thereof.

[0061] Embodiment 21: An aerosol-generating member according to any one of embodiments 1 to 20, wherein the substrate comprises one or more of calcium carbonate, alginate, one or more cellulose derivatives, starch, wood pulp, or tobacco-derived fibers.

[0062] Embodiment 22: An aerosol-generating member described in any one of embodiments 1 to 21, wherein the two or more aerosol-forming 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: An aerosol-generating member according to any one of embodiments 1 to 22, wherein the two or more aerosol-forming materials are glycerol and propylene glycol.

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

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

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

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

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

[0069] Embodiment 29: The aerosol-generating member of embodiment 28, wherein the substrate is impregnated with two or more aerosol-forming materials at a loading of about 15 to about 30 wt %, based on the total weight of the impregnated substrate.

[0070] Embodiment 30: The aerosol-generating member according to embodiment 28 or 29, 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.

[0071] Embodiment 31: The aerosol-generating member according to any one of embodiments 28 to 30, 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.

[0072] Embodiment 32: An aerosol-generating member described in any one of embodiments 28 to 31, 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.

[0073] Embodiment 33: The aerosol-generating member of any one of embodiments 28 to 31, wherein the first aerosol-forming material is glycol and the second aerosol-forming material is 1,3-propanediol, triethylene glycol, palmitic acid, or triacetin.

[0074] Embodiment 34: The aerosol-generating member of any one of embodiments 28 to 31, wherein the first aerosol-forming material is glycerol and the second aerosol-forming material is palmitic acid.

[0075] Embodiment 35: An aerosol generating member described in any one of embodiments 28 to 31, wherein the first aerosol forming material is 1,3-propanediol, triethylene glycol, 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 member described in any one of embodiments 28 to 31, wherein the substrate is impregnated with a third aerosol-forming material selected from the group consisting of glycerol, palmitic acid, and 1,3-propanediol, triethylene glycol, propylene glycol, triacetin, polyethylene glycol 400, sorbitan tristearate, and polysorbate 80.

[0077] Embodiment 37: An aerosol-generating member described in any one of embodiments 28 to 31, wherein the base material is impregnated with a mixture selected from the group consisting of glycerol and palmitic acid; glycerol and 1,3-propanediol; glycerol 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; propylene glycol and palmitic acid; propylene glycol and polyethylene glycol; and propylene glycol and polysorbate 80.

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

[0079] Embodiment 39: An aerosol-generating member according to any one of embodiments 28 to 31, wherein the substrate is impregnated with a mixture comprising glycerol, palmitic acid, and propylene glycol.

[0080] Embodiment 40: The aerosol generating member of embodiment 39, further comprising triacetin.

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

[0082] Embodiment 42: An aerosol-generating member according to any one of embodiments 28 to 41, wherein 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.

[0083] Embodiment 43: An aerosol generating member as described in embodiment 42, wherein the one or more binders are selected from alginates, cellulose derivatives, starches, gums, dextran, carrageenan, calcium carbonate, or combinations thereof.

[0084] Embodiment 44: An aerosol-generating member according to any one of embodiments 28 to 43, wherein the substrate comprises: about 40 to about 70% by weight of tobacco-derived fiber; about 10 to about 15% by weight of a cellulose derivative; and about 5 to about 10% by weight of wood pulp.

[0085] Embodiment 45: An aerosol-generating member according to any one of embodiments 28 to 44, further impregnated with a substrate, a flavourant, an active ingredient, or a combination thereof.

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

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

[0088] Embodiment 48: An aerosol-generating member according to any one of embodiments 28 to 47, wherein the substrate is in the form of particles, shreds, a film, a paper process sheet, a cast sheet, beads, granules, a rod, or an extrudate.

[0089] Embodiment 49: The aerosol-generating member according to any one of embodiments 28 to 48, wherein the substrate is formed in a substantially cylindrical shape.

[0090] Embodiment 50: An aerosol delivery device comprising an aerosol generating member described in any one of embodiments 1 to 49, a heat source configured to heat the impregnated substrate to form an aerosol, and an aerosol pathway extending from the aerosol generating member to a mouth end of the aerosol delivery device.

[0091] Embodiment 51: An aerosol delivery device as described in embodiment 50, wherein the heat source comprises either an electric 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 described in embodiment 50 or 51, wherein the heat source is an electric heating element.

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

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

[0096] These and other features, aspects, and advantages of the present disclosure will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which are briefly described below. The present invention includes any combination of two, three, four, or more of the above-described embodiments, and any combination of any two, three, four, or more features or elements described in this disclosure, whether or not such features or elements are explicitly combined in the description of a particular embodiment herein. The present disclosure is intended to be read in its entirety, and unless otherwise clearly indicated by the context, any separable features or elements of the disclosed invention should be construed as combinable as intended in any of its various aspects and embodiments.

[0097] Having thus described aspects of the present disclosure in the foregoing general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and which are merely illustrative and should not be construed as limiting the disclosure. [Brief description of the drawings]

[0098] [Figure 1] 1 shows a perspective view of an aerosol delivery device including a regulator and an aerosol generating member, the generating member and the regulator being connected to one another according to an exemplary embodiment of the present disclosure. [Diagram 2] 2 shows a perspective view of the aerosol delivery device of FIG. 1, in which the aerosol generating member and the control body are separated from each other according to an exemplary embodiment of the present disclosure. [Diagram 3] 1 shows a schematic perspective view of an aerosol generating member according to an exemplary embodiment of the present disclosure; [Figure 4] 1 shows a schematic cross-sectional view of a substrate portion of an aerosol-generating member according to an exemplary embodiment of the present disclosure. [Diagram 5] 1 shows a perspective view of an aerosol generating member according to an exemplary embodiment of the present disclosure. [Figure 6] 6 shows a perspective view of the aerosol generating member of FIG. 5 with the outer wrap removed, according to one embodiment of the present disclosure. [Figure 7] 1 is a bar graph showing the heat energy required to vaporize glycerol, propylene glycol, and mixtures thereof as measured by Differential Scanning Calorimetry (DSC). [Figure 8] FIG. 1 is a graphical representation of overlaid ion current curves of glycerol for paper processing reconstituted samples with various glycerol-propylene glycol loadings. [Figure 9] 1 is a graphical representation of overlaid glycerol ion current curves for beaded tobacco samples with various glycerol-propylene glycol loadings. [Figure 10] 1 is a graphical representation of overlaid thermogravimetric thermograms for aerosol-forming material mixtures. [Figure 11] 1 is a graphical representation of overlaid thermogravimetric analysis thermograms for a handsheet substrate impregnated with an aerosol-forming material mixture. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0099] The present disclosure will now be described more fully hereinafter with reference to exemplary embodiments thereof. These exemplary embodiments are described so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Indeed, the disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein, but rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements.

[0100] In this specification and the claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0101] The term "about" used throughout this specification is used to indicate and describe small variations. For example, the term "about" can refer to values ​​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%. All numerical values ​​in this specification are modified by the term "about", whether or not expressly stated. Values ​​modified by the term "about" are, of course, inclusive of the specified value. For example, "about 5.0" must include 5.0.

[0102] References to "dry weight percent" or "dry weight basis" refer to weight based on dry ingredients (i.e., all ingredients excluding water). All weight percentage values ​​herein are dry weight percent unless otherwise indicated.

[0103] As described below, an exemplary embodiment of the present disclosure relates to an aerosol-generating member comprising a substrate of two or more aerosol-forming materials, including a first aerosol-forming material and a second aerosol-forming material, each of which has a different boiling point, a different vapor pressure, or both. A further exemplary embodiment of the present disclosure relates to an aerosol delivery device comprising an aerosol-generating member as disclosed herein, a heat source configured to heat the aerosol-forming materials impregnated in the substrate portion to form an aerosol, and an aerosol pathway extending from the aerosol-generating member to a mouth end of the aerosol delivery device.

[0104] Aerosol generating member and aerosol delivery device Some embodiments of the aerosol generating members according to the present disclosure use electrical energy to heat the material to form the inhaled substance (e.g., electrically heated tobacco products). Other embodiments of the aerosol generating members according to the present disclosure use an pyrophoric heat source to heat the material to form the inhaled substance (e.g., carbon heated tobacco products), preferably without burning the material to any significant extent. Preferably, the material is heated without burning the material to any significant extent. The members of such systems have the form of an article that is compact enough to be considered a handheld device. That is, the use of the preferred aerosol delivery device members does not result in the production of smoke in the sense that the aerosol is primarily derived from the by-products of tobacco combustion or pyrolysis, rather, the use of the preferred systems results in the production of vapor resulting from the volatilization or vaporization of certain components incorporated therein. In some exemplary embodiments, the members of the aerosol delivery device may be characterized as electronic cigarettes, which most preferably incorporate tobacco and / or tobacco-derived components and thus deliver tobacco-derived components in aerosol form.

[0105] The aerosol-generating member of certain preferred aerosol delivery devices does not burn any of its components to any substantial extent, and may provide many of the sensations (e.g., inhalation and exhalation patterns, types of tastes or flavors, sensory stimulant effects, physical feel, modes of use, visual cues such as those provided by a visible aerosol, etc.) of smoking a cigarette, cigar, or pipe used by lighting and burning tobacco (and thus inhaling tobacco smoke). For example, a user of an aerosol delivery device according to some exemplary embodiments of the present disclosure may hold and use the member as a smoker would use a traditional type of smoking article, drawing on one end of the member to inhale the aerosol generated by the member, puffing or inhaling at selected time intervals, etc.

[0106] Although the present system is generally described herein with respect to embodiments related to aerosol delivery devices and / or aerosol generating members, such as so-called "electronic cigarettes" or "tobacco heating products," it should be understood that the features, members, features, and methods may be embodied in many different forms and associated with various components. For example, the description provided herein may be used with embodiments of traditional smoking articles (e.g., cigarettes, cigars, pipes, etc.), non-combustion heated cigarettes, and related packaging for any of the products disclosed herein. Thus, it should be understood that the description of the features, members, features, and methods disclosed herein are described with respect to embodiments related to aerosol delivery devices by way of example only, and may be embodied and used in a variety of other products and methods.

[0107] The aerosol delivery device and / or aerosol generating member of the present disclosure may also be characterized as being a vapor product or drug delivery article. Thus, such articles or devices may be adapted to provide one or more substances (e.g., flavors and / or pharmaceutical actives) in an inhalable form or state. For example, the inhaled substance may be substantially in the form of a vapor (i.e., a substance in the gas phase at a temperature below its critical point). Alternatively, the inhaled substance may be in the form of an aerosol (i.e., a suspension of fine solid particles or of liquid droplets in a gas). For simplicity, as used herein, the term "aerosol" is meant to include vapors, gases, and aerosols in any form or type suitable for human inhalation, whether or not visible and whether or not in a form that may be considered smoky. The physical form of the inhaled substance is not necessarily limited by the nature of the device of the present invention, but rather may depend on the nature of the medium and of the inhaled substance itself, as to whether it exists in a vapor state or an aerosol state. In some embodiments, the terms "vapor" and "aerosol" may be interchangeable. Thus, for simplicity, the terms "vapor" and "aerosol" used to describe aspects of the present disclosure are understood to be interchangeable, unless otherwise specified.

[0108] In some embodiments, the aerosol delivery device of the present disclosure may comprise some combination of aerosol generating components including a power source (e.g., a power source), at least one control member (e.g., a means for activating, controlling, regulating and terminating power for heat generation, such as by controlling the flow of current from the power source to other components of the article, e.g., a microprocessor, either individually or as part of a microcontroller), a heat source (e.g., an electrical resistance heater or other member and / or an induction coil or other associated member and / or one or more radiative heating elements), and a substrate portion capable of generating an aerosol upon application of sufficient heat. It is noted that it is possible to physically combine one or more of the above components. For example, in certain embodiments, conductive heater traces can be printed onto the surface of the substrate material described herein (e.g., a nanocellulose substrate film) using conductive inks, such that the heater traces can be powered by a power source and used as a resistive heater. Examples of conductive inks include graphene inks and inks containing various metals, such as inks containing silver, gold, palladium, platinum and alloys or other combinations thereof (e.g., silver-palladium or silver-platinum inks), which may be printed onto a surface using processes such as gravure printing, flexography, offset printing, screen printing, inkjet printing, or other suitable printing methods.

[0109] In various embodiments, many of these components may be provided within an outer body or shell, which in some embodiments may be referred to as a housing. The overall design of the outer body or shell may vary, and the shape or configuration of the outer body may vary, which may define the overall size and shape of the aerosol delivery device. In some embodiments, the elongated body resembling the shape of a cigarette or cigar may be formed from a single integral housing, or the elongated housing may be formed from two or more separable bodies, although other configurations are possible. For example, the aerosol delivery device may be substantially tubular in shape and thus comprise an elongated shell or body resembling the shape of a conventional cigarette or cigar. In one example, all of the components of the aerosol delivery device are contained within one housing or body. In other embodiments, the aerosol delivery device may comprise two or more housings that are joined and separable. For example, the aerosol delivery device may have a control body with a housing containing one or more reusable components (e.g., accumulators such as rechargeable batteries and / or rechargeable supercapacitors and various electronics for controlling the operation of the article) at one end, and an outer body or shell containing a disposable portion (e.g., a disposable flavor-containing aerosol generating component) removably connectable to the other end.

[0110] In other embodiments, the aerosol generating members of the present disclosure may generally comprise a pyrotechnic heat source configured to heat the substrate material. At least a portion of the substrate material and / or heat source may be covered with an outer wrap or wrapping, casing, member, module, element, etc. The overall design of the housing may vary, as may the shape or configuration of the housing, which defines the overall size and shape of the aerosol generating member. While other configurations are possible, in some aspects it may be desirable for the overall design, size and / or shape of these embodiments to be similar to that of a traditional cigarette or cigar. In various aspects, the heat source may be capable of generating heat to aerosolize substrate materials, including, for example, substrate materials associated with the aerosol-forming material, extruded structures and / or substrates, tobacco and / or tobacco-related materials, such as materials naturally found in tobacco, such as solid or liquid forms (e.g., beads, sheets, shreds, wraps), directly isolated from tobacco or synthetically prepared.

[0111] More specific shapes, configurations and arrangements of the various substrate materials, aerosol generating components and components within the aerosol delivery device of the present disclosure will become apparent in light of the further disclosure provided below. Additionally, the selection of the various aerosol delivery device components can be understood in light of commercially available electronic aerosol delivery devices. Furthermore, the arrangement of the components within the aerosol delivery device can be understood in light of commercially available electronic aerosol delivery devices.

[0112] In this regard, Fig. 1 illustrates an aerosol delivery device 100 according to an exemplary embodiment of the present disclosure. The aerosol delivery device 100 may include a control body 102 and an aerosol generating member 104. In various embodiments, the aerosol generating member 104 and the control body 102 may be permanently or removably aligned in a functional relationship. In this regard, Fig. 1 illustrates the aerosol delivery device 100 in a coupled configuration, while Fig. 2 illustrates the aerosol delivery device 100 in a separated configuration. Various mechanisms can connect the aerosol generating member 104 to the control body 102 to provide a threaded engagement, a press fit engagement, an interference fit, a sliding fit, a magnetic engagement, and the like.

[0113] In various embodiments, the aerosol delivery device 100 according to the exemplary embodiments of the present disclosure can have a variety of overall shapes, including, but not limited to, an overall shape that may be defined as being substantially rod-like or substantially tubular or substantially cylindrical. In the embodiment of FIGS. 1-2, the device 100 has a substantially circular cross-section, although other cross-sectional shapes (e.g., oval, square, triangular, etc.) are also encompassed by the present disclosure. For example, in some embodiments, either or both of the control body 102 or the aerosol generation member 104 (and / or any sub-members) may have a substantially rectangular shape, such as a substantially rectangular cuboid shape (e.g., similar to a USB flash drive). In other embodiments, either or both of the control body 102 or the aerosol generation member 104 (and / or any sub-members) may have other handheld shapes. For example, in some embodiments, the control body 102 may have a small box shape, various podmod shapes, or a fob-shape. Thus, such language describing the physical form of the article may also apply to its individual components, including the control body 102 and the aerosol-generating member 104.

[0114] The arrangement of components within the aerosol delivery device of the present disclosure may vary across various embodiments. In some embodiments, the substrate portion may be positioned in close proximity to the heat source to maximize delivery of the aerosol to the user. However, other configurations are not excluded. In general, the heat source may be positioned in sufficient proximity to the substrate portion such that heat from the heat source can volatilize the substrate portion (and in some embodiments, one or more flavorants, medicinal agents, etc., which may also be provided for delivery to the user) to form an aerosol for delivery to the user. When the heat source heats the substrate portion, an aerosol is formed, released, or generated in a physical form suitable for inhalation by the consumer. It should be noted that the foregoing terms are meant to be interchangeable, such that references to release, releasing, releases, or released include form or generate, forming or generating, forms or generates, and formed or generated. Specifically, the inhalant is released in the form of a vapor or an aerosol or a mixture thereof, and such terms are also used interchangeably herein, except where otherwise noted.

[0115] As mentioned above, the aerosol delivery device 100 of various embodiments can incorporate a battery and / or other power source to provide sufficient current to provide various functionalities to the aerosol delivery device, such as powering a heat source, powering a control system, powering an indicator, etc. As described in more detail below, the power source can take various embodiments. Preferably, the power source can deliver sufficient power to quickly activate the heat source to be provided for aerosol formation, and power the aerosol delivery device through a desired duration of use. In some embodiments, the power source is sized to conveniently fit within the aerosol delivery device so that the aerosol delivery device can be easily handled. Examples of useful power sources include lithium ion batteries, preferably rechargeable (e.g., rechargeable lithium manganese dioxide batteries). In particular, lithium polymer batteries that can be used as such batteries can enhance safety. Other types of batteries, such as N50-AAA CADNICA nickel cadmium batteries, can also be used. Additionally, the preferred power source is lightweight enough not to impair the desired smoking experience. Some examples of possible power sources are described in U.S. Pat. No. 9,484,155 to Peckerar et al. and U.S. Patent Application Publication No. 2017 / 0112191 to Sur et al., filed October 21, 2015, the disclosures of which are each incorporated by reference in their entirety herein.

[0116] In certain embodiments, one or both of the controller 102 and the aerosol-generating member 104 may be referred to as disposable or reusable. For example, the controller 102 may have a replaceable or rechargeable battery, an all-solid-state battery, a thin-film solid-state battery, a rechargeable supercapacitor, etc., and thus may be combined with any type of charging technology, including connection to a wall charger, connection to a car charger (e.g., cigarette lighter outlet) and connection to a computer via a Universal Serial Bus (USB) cable or connector (e.g., USB 2.0, 3.0, 3.1, USB Type-C), connection to a solar panel of photovoltaic cells (sometimes referred to as solar cells) or solar cells, wireless chargers, such as chargers using inductive wireless charging (e.g., including wireless charging compliant with the Wireless Power Consortium (WPC) Qi wireless charging standard) or wireless radio frequency (RF)-based chargers. An example of an inductive wireless charging system is 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 member 104 may comprise a single-use device. A single-use member for use with a regulator is disclosed in U.S. Patent No. 8,910,639 to Chang et al., which is incorporated herein by reference in its entirety.

[0117] In a further embodiment, the power source may also include a capacitor. The capacitor can discharge faster than the battery and can be charged during a puff, so that the battery can discharge into the capacitor at a slower rate than if it were to directly power the heat source. For example, a supercapacitor, such as an electric double layer capacitor (EDLC), can be used separately from or in combination with the battery. When used alone, the supercapacitor may be recharged before each use of the article. Thus, the device may also include a charger member that can be attached to the smoking article during use to replenish the supercapacitor.

[0118] Additional components may be utilized in the aerosol delivery device of the present disclosure. For example, the aerosol delivery device may include a flow sensor that is sensitive to either pressure or airflow changes when the consumer inhales the article (e.g., a puff-activated switch). Other possible current activation / deactivation mechanisms may include a temperature-activated on / off switch or a lip pressure-activated switch. An example of a mechanism that can provide such a puff-activated function is the Model 163PC01D36 silicon sensor manufactured by the MicroSwitch division of Honeywell, Inc. of Freeport, Illinois. Representative flow sensors, current regulation components, and other current control components, including various microcontrollers, sensors, and switches for aerosol delivery devices are described in U.S. Patent No. 4,735,217 to Gerth et al., U.S. Patent Nos. 4,922,901, 4,947,874, and 4,947,875, all to Brooks et al., U.S. Patent No. 5,372,148 to McCafferty et al., U.S. Patent No. 6,040,560 to Fleischhauer et al., U.S. Patent No. 7,040,314 to Nguyen et al., and U.S. Patent No. 8,205,622 to Pan, all of which are incorporated herein by reference in their entireties. Also reference is made to the control scheme described in U.S. Patent No. 9,423,152 to Ampolini et al., which is incorporated herein by reference in its entirety.

[0119] In another example, the aerosol delivery device may comprise a first conductive surface configured to contact a first body part of a user holding the device and a second conductive surface conductively 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 is inhaled by the user holding the unit. The first body part and the second body part may be the lips or the hand. The two conductive surfaces may also be used to charge a battery contained in the personal vaporizer unit. The two conductive surfaces may also form or be part of a connector that may be used to output data stored in the memory. See U.S. Patent No. 9,861,773 to Terry et al., which is incorporated herein by reference in its entirety.

[0120] Additionally, 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 that can be associated with the mouth end of the device to detect the user's lip action associated with inhalation and trigger heating of the heating device; U.S. Patent No. 5,372,148 to McCafferty et al. discloses a puff sensor for controlling energy flow to a heating load array in response to a pressure drop through the mouthpiece; U.S. Patent No. 5,967,148 to Harris et al. discloses a receptacle in a smoking device that includes an identifier that detects non-uniformity in infrared transmittance of an inserted member and a controller that executes a detection routine when a member is inserted into the receptacle; U.S. Patent No. 6,040,560 to Fleischhauer et al. describes defined executable power cycles with multiple differential phases; and U.S. Patent No. 5,934,289 to Watkins et al. discloses a photonic No. 5,954,979 to Counts et al. discloses a means for altering the resistance of draw through a smoking device; U.S. Pat. No. 6,803,545 to Blake et al. discloses certain battery configurations for use in smoking devices; U.S. Pat. No. 7,293,565 to Griffen et al. discloses various charging systems for use with smoking devices; U.S. Pat. No. 8,402,976 to Fernando et al. discloses computer interface means for a smoking device to facilitate charging and enable computer control of the device; U.S. Pat. No. 8,689,804 to Fernando et al. discloses an identification system for a smoking device; and PCT International Publication No. WO 2010 / 003480 to Flick discloses a fluid flow sensing system for indicating puffs in an aerosol generation system, all of the foregoing disclosures are incorporated herein by reference in their entireties.

[0121] Further examples of electronic aerosol delivery articles that may be used in the device and components related to the disclosed materials or components 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. 7,896,006 to Hamano, U.S. Pat. No. 6,772,756 to Shayan, U.S. Pat. No. 6,772,756 to Hon, U.S. Pat. Nos. 8,156,944 and 8,375,957, U.S. Patent No. 8,794,231 to Thorens et al., U.S. Patent No. 8,851,083 to Oglesby et al., U.S. Patent Nos. 8,915,254 and 8,925,555 to Monsees et al., U.S. Patent No. 9,220,302 to DePiano et al., U.S. Patent Application Publication No. 2006 / 0196 to Hon 518 and 2009 / 0188490, U.S. Patent Application Publication No. 2010 / 0024834 to Oglesby et al., U.S. Patent Application Publication No. 2010 / 0307518 to Wang, PCT International Publication No. WO2010 / 091593 to Hon, and PCT International Publication No. WO2013 / 089551 to Foo, each of which is incorporated herein by reference in its entirety. Additionally, U.S. Patent Application Publication No. 2017 / 0099877 to Worm et al., filed October 13, 2015, discloses capsules that may be included in an aerosol delivery device and fob configurations for an aerosol delivery device, which are incorporated herein by reference in their entirety. Various materials disclosed by the aforementioned documents may be incorporated into the device in various embodiments, and all of the aforementioned disclosures are incorporated herein by reference in their entirety.

[0122] 2, in the depicted embodiment, the aerosol generating member 104 includes a heating end 106 configured to be inserted into the control body 102 and a mouth end 108 that a user inhales to create an aerosol. At least a portion of the heating end 106 may include a substrate portion 110. As described 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 member 104 or a portion thereof may be wrapped with an outer overwrap material 112. In various embodiments, the mouth end 108 of the aerosol generating member 104 may include a filter 114, for example, made of a cellulose acetate or polypropylene material. The filter 114 may additionally or alternatively contain strands of tobacco-containing 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 may increase the structural integrity of the mouth end of the aerosol source element and / or provide filtering capabilities and / or resistance to retraction if desired. In some embodiments, the filter may comprise separate segments. For example, some embodiments may include a segment that provides filtering, a segment that provides resistance to retraction, a hollow segment that provides space for cooling the aerosol, a segment that provides increased structural integrity, other filter segments, and any one or any combination of the above.

[0123] In some embodiments, the material of the outer overwrap 112 may include a material that resists the transfer of heat, which may include paper or other fibrous materials, such as cellulosic materials. The outer overwrap material may also include at least one filler material embedded or dispersed within the fibrous material. In various embodiments, the filler material may have the form of water-insoluble particles. Additionally, the filler material may incorporate inorganic members. In various embodiments, the outer overwrap may be formed from multiple layers, such as an underlying bulk layer and an overlying layer, such as a typical cigarette wrapper. Such materials may include, for example, lightweight "rag fibers," such as flax, thyme, sisal, rice straw, and / or esperma. The outer overwrap may also include materials typically used in conventional cigarette filter elements, such as cellulose acetate. Additionally, the excess length of the outer overlap at the mouth end 108 of the aerosol generating member can function to simply separate the substrate portion 110 from the consumer's mouth, or to provide space for placement of a filter material, or to affect suction on the article, or to affect the flow characteristics of the vapor or aerosol exiting the device during inhalation, as described below. Further description of the configuration of outer overlap materials that may be used with the present disclosure may be found in U.S. Patent No. 9,078,473 to Worm et al., which is incorporated herein by reference in its entirety.

[0124] In various embodiments, other components may be present between the substrate portion 110 and the mouth end 108 of the aerosol generating member 104. For example, in some embodiments, one or any combination of the following may be disposed between the substrate portion 110 and the mouth end 108 of the aerosol generating member 104: an air gap, a hollow tube structure, a phase change material for cooling air, a flavor release medium, ion exchange fibers capable of selective chemical adsorption, aerogel 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 AgNO3, AlCl3, TaCl3, InCl3, SnCl2, AlI3, and TiI4, 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 US Pat. No. 8,430,106 to Potter et al., which is incorporated herein by reference in its entirety.

[0125] As described in more detail below, the presently disclosed aerosol generating members are configured for use with conductive and / or inductive heat sources to heat the substrate material to form an aerosol. In various embodiments, the conductive heat source may comprise a heating assembly including a resistive heating element. The resistive heating element may be configured to generate heat when an electric current is directed therethrough. Conductive materials useful as resistive heating elements may be those that have low mass, low density, and moderate resistivity, and are thermally stable at temperatures experienced during use. Useful heating elements heat and cool rapidly, thus providing efficient use of energy. The rapid heating of the element may be beneficial in providing nearly instantaneous volatilization of the aerosol-forming material in its vicinity. The rapid cooling prevents substantial volatilization (and thus waste) of the aerosol-forming material during periods when formation of an aerosol is not desired. Such heating elements may also allow for relatively precise control of the temperature range experienced by the aerosol-forming material, particularly when time-based current control is employed. Useful conductive materials are preferably chemically non-reactive with the materials being heated (e.g., aerosol-forming materials and other inhalant materials) so as not to adversely affect the flavor or content of the aerosol or vapor being generated. Some exemplary, non-limiting materials that can be used as conductive materials include carbon, graphite, carbon / graphite composites, metals, ceramics, such as metal and nonmetal carbides, nitrides, oxides, silicides, intermetallic compounds, cermets, metal alloys, and metal foils. In particular, refractory materials may be useful. A variety of different materials can be mixed to achieve the desired properties of resistance, mass, and thermal conductivity. In certain embodiments, metals that can be utilized include, for example, nickel, chromium, alloys of nickel and chromium (e.g., nichrome), and steel.Materials that may be useful for providing resistive heating are described in U.S. Pat. No. 5,060,671 to Counts et al., U.S. Pat. No. 5,093,894 to Deevi et al., U.S. Pat. No. 5,224,498 to Deevi et al., and U.S. Pat. No. 5,224,498 to Sprinkel et al. No. 5,228,460 to Jr. et al., No. 5,322,075 to Deevi et al., U.S. Pat. No. 5,353,813 to Deevi et al., No. 5,468,936 to Deevi et al., U.S. Pat. No. 5,498,850 to Das, U.S. Pat. No. 5,659,656 to Das, U.S. Pat. No. 5,498,855 to Deevi et al., U.S. Pat. No. 5,530,225 to Hajaligol, U.S. Pat. No. 5,665,262 to Hajaligol, U.S. Pat. No. 5,573,692 to Das et al., and U.S. Pat. No. 5,591,368 to Fleischhauer et al., the disclosures of which are incorporated herein by reference in their entireties.

[0126] In various embodiments, the heating element may be provided in a variety of forms, such as foils, foams, meshes, hollow balls, half balls, disks, helices, fibers, wires, films, yarns, strips, ribbons, or cylinders. Such heating elements often include metallic materials and are configured to generate heat as a result of electrical resistance associated with passing an electric current therethrough. Such resistive heating elements may be disposed in close proximity to and / or in direct contact with the substrate portion. For example, in one embodiment, the heating element may comprise a cylinder or other heating device disposed within the control body 102, the cylinder being constructed of one or more conductive materials, including, but not limited to, copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, carbon (e.g., graphite), or any combination thereof. In various embodiments, the heating element may also be coated with any of these or other conductive materials. The heating element may be disposed in close proximity to the engagement end of the control body 102 and may be configured to substantially surround a portion of the heating end 106 of the aerosol generating member 104, including the substrate portion 110. In this manner, when the aerosol source element is inserted into the control body 102, the heating element may be disposed proximate to the substrate portion 110 of the aerosol generating member 104. In other examples, when the aerosol generating member is inserted into the control body, at least a portion of the heating element may penetrate at least a portion of the aerosol generating member (e.g., one or more prongs and / or spikes that penetrate the aerosol generating member, etc.). It should be noted that while in some embodiments the heating element may comprise a cylinder, in other embodiments the heating element may take various forms and in some embodiments may directly contact and / or penetrate the substrate portion.

[0127] In addition to being configured for use with conductive heat sources as described above, the present disclosure may also be configured for use with inductive heat sources that heat a substrate portion to form an aerosol. In various embodiments, the inductive heat source may comprise a resonant transformer that may comprise a resonant transmitter and a resonant receiver (e.g., a susceptor). In some embodiments, the resonant transmitter and the resonant receiver may be disposed in the control body 102. In other embodiments, the resonant receiver or a portion thereof may be disposed in the aerosol source element 104. For example, in some embodiments, the control body 102 may include a resonant transmitter and a resonant receiver that may comprise, for example, a foil material, a coil, a cylinder, or other structure configured to generate an oscillating magnetic field, and the resonant receiver may comprise one or more prongs that extend into or are surrounded by the substrate portion. In some embodiments, the aerosol generation member is in intimate contact with the resonant receiver.

[0128] In other embodiments, the resonant transmitter may comprise a helical coil configured to surround the cavity in which the aerosol generating member, particularly the substrate portion of the aerosol generating member, is received. In some embodiments, the helical coil may be disposed between the outer wall of the device and the receiving cavity. In one embodiment, the coil winding may have a circular cross-sectional shape, while 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 into a portion of the receiving cavity, and the pin may comprise a resonant transmitter, for example, by including a coil structure around or within the pin. In various embodiments, an aerosol source element may be received within the receiving cavity, and one or more members of the aerosol source element may function as a resonant receiver. In some embodiments, the aerosol generating member comprises a resonant receiver. Other possible resonant transformer components, including resonant transmitters and receivers, are described in U.S. Patent Application Publication No. 15 / 799,365, filed October 31, 2017, entitled "Induction Heated Aerosol Delivery Device," which is hereby incorporated by reference in its entirety.

[0129] Base material As noted above, in various embodiments, the substrate portion 110 can include a variety of substrate materials impregnated with two or more aerosol-forming materials. In some embodiments, the substrate includes tobacco-derived fibers, wood, wood-derived fibers, or combinations thereof.

[0130] In various implementations, the tobacco-derived fibers may include ground tobacco materials. Tobacco materials that may be useful in the present disclosure may vary and may include, for example, flue-cured tobacco, burley tobacco, oriental or Maryland tobacco, dark tobacco, dark-fired tobacco, and Rustica tobacco, as well as other rare or specialty tobaccos, or blends thereof. Tobacco materials may also include so-called "blend" forms and processed forms, such as processed tobacco stems (e.g., cut-rolled or cut-puffed stems), volume-expanded tobacco (e.g., puffed tobacco, such as dry ice expanded tobacco (DIET), preferably in cut filler form), and reconstituted tobacco (e.g., reconstituted tobacco produced using a paper-making or cast sheet process). Various representative tobacco types, tobacco process types, and tobacco blend types are described in U.S. Pat. No. 4,836,224 to Lawson et al., U.S. Pat. No. 4,924,888 to Perfetti et al., U.S. Pat. No. 5,056,537 to Brown et al., U.S. Pat. No. 5,159,942 to Brinkley et al., U.S. Pat. No. 5,220,930 to Gentry, U.S. Pat. No. 5,360,023 to Blakley et al., U.S. Pat. No. 5,360,023 to S. Hafer et al., U.S. Patent No. 6,701,936, Li et al., U.S. Patent No. 7,011,096, Li et al., U.S. Patent No. 7,017,585, Lawson et al., U.S. Patent No. 7,025,066, Perfett, U.S. Patent Application Publication No. 2004-0255965, Bereman et al., WO 02 / 37990, and Bombick et al., Fund. Appl. Toxicol., Vol. 39, pp. 11-17 (1997). Further examples of tobacco compositions that may be useful are Robinson et al., U.S. Patent No. 7,726,320, the entire contents of which are incorporated herein by reference. In some implementations, the ground tobacco material may include a flavorful and aromatic tobacco blend.In another implementation, the tobacco material can include reconstituted tobacco materials, such as those described in U.S. Patent No. 4,807,809 to Pryor et al., U.S. Patent No. 4,889,143 to Pryor et al., and U.S. Patent No. 5,025,814 to Raker, the entire contents of which are incorporated herein by reference. Additionally, the reconstituted tobacco material can include reconstituted tobacco paper for cigarette configuration, as described in Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco, RJ Reynolds, Tobacco Company Monograph (1988), the entire contents of which are incorporated herein by reference.

[0131] In certain embodiments, the substrate comprises a reconstituted tobacco material, for example using various casting and papermaking techniques known in the art. The reconstituted tobacco material may comprise wood pulp, tobacco fiber, plant matter, or other cellulose components. In some embodiments, the addition of nanocellulose material to the reconstituted tobacco material may help to enhance both the absorbency and mechanical strength of the resulting material. Reconstituted tobacco materials, and methods of providing such 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. 5,025,611 to Raker, all of which are incorporated herein by reference in their entireties. 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. 6,216,707 to Kumar.

[0132] In some embodiments, the substrate comprises, by weight, about 0 to about 80% tobacco-derived fiber, about 0 to about 40% tobacco-derived fiber, or about 20 to about 40% tobacco-derived fiber. In some embodiments, the substrate comprises, for example, 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 fiber.

[0133] In some implementations, the substrate comprises a plant-derived non-tobacco material, such as, but not limited to, tamarind, flax, sisal, rice straw, esperma grass, and / or cellulose pulp material. In various other implementations, the substrate material may comprise reconstituted tobacco by itself or in combination with other fibrous materials. Some exemplary embodiments and methods for providing reconstituted tobacco sheets, including 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. 6,216,707 to Kumar, which are incorporated herein by reference in their entireties. In some cases, processed tobacco, such as certain types of reconstituted tobacco, may be used as longitudinally extending strands. See, for example, the types of configurations described in U.S. Patent No. 5,025,814 to Raker, which is incorporated by reference in its entirety. Additionally, certain types of reconstituted tobacco sheets may be formed, rolled, or gathered into a desired configuration. In still other implementations, the substrate material may include various types of inorganic fibers (e.g., fiberglass, metal wire / screen, etc.) and / or (organic) synthetic polymers). In various implementations, these "fibrous" materials may be unstructured (e.g., randomly distributed like cellulose fibers in a tobacco cast sheet) or structured (e.g., wire mesh).

[0134] In some embodiments, the substrate comprises, by weight, about 0 to about 5% wood fibers or wood-derived fibers, e.g., 0%, about 1%, about 2%, about 3%, about 4%, about 5% wood fibers or wood-derived fibers.

[0135] In some embodiments, the substrate portion 110 may further include a fire-resistant material, conductive fibers or particles for thermal conduction / induction, or any combination thereof. One example of a fire-resistant material is ammonium phosphate. In some embodiments, other flame / burn retardant materials and additives may be included in the substrate portion 110, including organophosphorus compounds, borax, alumina trihydrate, graphite, potassium, silica, tripolyphosphate, dipentaerythritol, pentaerythritol, and polyols. Other fire-resistant materials, such as nitrogen-containing phosphonates, monoammonium phosphate, ammonium polyphosphate, ammonium bromide, ammonium borate, ethanol ammonium borate, ammonium sulfamate, halogenated organic compounds, thiourea, and antimony oxide may also be used. In each embodiment of the flame retardant, fire resistant and / or char retardant materials used in the substrate material and / or in other components (alone or in combination with each other and / or other materials), the desired properties are those that do not depend on and are resistant to undesirable gassing or melting behavior.Various embodiments and methods for incorporating tobacco into smoking articles, and in particular smoking articles designed to intentionally not combust substantially all of the tobacco within those smoking articles, are described in U.S. Patent No. 4,947,874 to Brooks et al., U.S. Patent No. 7,647,932 to Cantrell et al., U.S. Patent No. 8,079,371 to Robinson et al., U.S. Patent No. 7,290,549 to Banerjee et al., and U.S. Patent Application Publication No. US 2007 / 0215167 to Crooks et al., the entire disclosures of which are incorporated herein by reference.

[0136] As noted above, the substrate portion 110 may also include conductive fibers or particles for heating by thermal conduction or induction. In some embodiments, the conductive fibers or particles may be arranged in a substantially series and parallel pattern. In some embodiments, the conductive fibers or particles may be arranged substantially randomly. In some embodiments, the conductive fibers or particles may be comprised of aluminum materials, stainless steel materials, copper materials, carbon materials, graphite materials, and the like. In some embodiments, one or more conductive fibers or particles having different Curie temperatures may be included in the substrate material to facilitate inductive heating at various temperatures.

[0137] In some embodiments, the substrate further comprises 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 combinations thereof. Other examples of binder materials are described, for example, in U.S. Patent No. 5,101,839 to Jakob et al. and U.S. Patent No. 4,924,887 to Raker et al., which are incorporated herein by reference in their entireties.

[0138] In some embodiments, the one or more binders are alginates, such as ammonium alginate, propylene glycol alginate, potassium alginate, and sodium alginate. Alginates, especially high viscosity alginates, may be used in combination with controlled levels of free calcium ions. In some embodiments, the substrate comprises about 0 to about 10% alginate by weight, such as about 0%, about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about 10% alginate.

[0139] 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 cellulose derivatives, e.g., two or three cellulose derivatives). In some embodiments, the substrate includes, by weight, about 0 to about 5% of one or more cellulose derivatives, e.g., about 0%, about 1%, about 2%, about 3%, about 4%, about 5% of one or more cellulose derivatives. In embodiments where the substrate includes more than one cellulose derivative, it should be understood that the weight basis set forth for about 0 to about 5% of one or more cellulose derivatives reflects the total weight of the combination of cellulose derivatives.

[0140] In some embodiments, the cellulose derivative comprises a nanocellulose material. As used herein, "nanocellulose material" refers to a cellulose material having at least one average particle size dimension in the range of about 1 nm to about 100 nm. Larger cellulose material sizes may be used, but reduced aerosol-forming material loadings are likely to occur. As non-limiting examples, suitable nanocellulose materials may be fibrous materials prepared from any of a variety of cellulose-containing materials, such as wood (e.g., eucalyptus trees), grasses (e.g., bamboo), cotton, tobacco, algae, and other plant-based materials, where the fibers are further refined to produce nanofibrillated cellulose fibers. In various embodiments, the nanocellulose material may contain one or more of tobacco-derived nanocellulose fibers and / or non-tobacco-derived nanocellulose fibers, optionally in combination with one or more additional cellulose materials, such as tobacco-derived cellulosic pulp and / or wood pulp-based cellulose fibers. In some embodiments, the binder material may comprise nanocellulose derived from tobacco or other biomass.

[0141] In some embodiments, one or more cellulose derivatives are chemically modified cellulose derivatives.Suitable chemically modified cellulose derivatives include hydroxypropyl cellulose, such as Klucel H from Aqualon; hydroxypropyl methylcellulose, such as Methocel K4MS from Dow Chemical; hydroxyethyl cellulose, such as Natrosol 250 MRCS from Aqualon; microcrystalline cellulose, such as Avicel from FMC; methylcellulose, such as Methocel A4M from Dow Chemical; and sodium carboxymethylcellulose, such as CMC 7HF and CMC 7H4F from Hercules.

[0142] In some embodiments, the one or more binders are starches. In some embodiments, the substrate comprises, by weight, about 0-30% starch, about 0-15% starch, or about 20-40% starch. In some embodiments, the substrate comprises, for example, about 0%, about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, or about 40% starch. Suitable starches include corn starch, rice starch, and modified food starch. In some other embodiments, the binder is rice starch. In some embodiments, the one or more binders are dextran. In some other embodiments, the binder may comprise cyclodextrin.

[0143] 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.

[0144] In some embodiments, the one or more binders is carrageenan.

[0145] In some embodiments, the one or more binders are calcium carbonate. In some embodiments, the substrate comprises, by weight, about 0-60% calcium carbonate, about 45-60% calcium carbonate, about 40-60% calcium carbonate, or about 5-15% calcium carbonate. In some embodiments, the substrate comprises, for example, 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.

[0146] In some embodiments, the substrate comprises, by weight, 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 fiber.

[0147] In some embodiments, the substrate comprises, by weight, about 0 to about 5% calcium carbonate, about 1 to about 5% wood pulp, and about 70 to about 80% tobacco-derived fiber.

[0148] In some embodiments, the substrate comprises, by weight, 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 fiber.

[0149] In some embodiments, the substrate comprises, by weight, 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 fiber.

[0150] In some embodiments, the substrate comprises, by weight, about 5 to 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 fiber.

[0151] In some embodiments, the substrate comprises tobacco-derived fiber, wood-derived fiber, or a combination thereof, and one or more binders, hi some embodiments, the one or more binders are selected from alginates, cellulose derivatives, starches, gums, dextran, carrageenan, calcium carbonate, or a combination thereof.

[0152] In some embodiments, the substrate comprises, on a weight basis, about 40 to about 70 weight percent tobacco-derived fiber, about 10 to about 15 weight percent cellulose derivative, and about 5 to about 10 weight percent wood pulp, in some embodiments, the cellulose derivative is carboxymethyl cellulose.

[0153] The moisture (e.g., water) content of the substrate may vary, In some embodiments, the substrate comprises water in an amount of up to about 10% by weight, based on the total dry weight of the impregnated substrate (e.g., a substrate containing an aerosol-forming material after drying to remove excess water added during processing).

[0154] In some embodiments, the substrate is in particulate form, shredded form, film form, paper process sheet form, cast sheet form, bead form, granular rod form, or extrudate form. In various embodiments, the form of the substrate portion 110 can include gels, shreds, films, suspensions, extrudates, shavings, capsules, and / or particles (e.g., pellets, beads, strips, or any desired particle shape of various sizes), and combinations thereof. In some embodiments, the substrate is formed into a substantially cylindrical shape.

[0155] In some embodiments, the substrate is prepared using paper processing techniques, and the resulting sheet may be further divided into cut lugs or strips for insertion into the substrate-containing segment of the aerosol delivery device. The preparation method generally involves hot water extraction (60-90°C) of tobacco pieces, stems, chips, or dust for a period of time. This is followed by separation (centrifugation and / or filter separation) into a weak extract containing solubles and a solid fraction containing unrefined fibers. The weak extract is then concentrated, for example by vacuum deposition or other means, to a >20% solid (weight / volume) extract. Optionally, one or more of two or more aerosol forming agents described herein may be added and thoroughly mixed to obtain a homogenous mixture. Water and pre-pulped wood fibers may be added to the tobacco solids, and the material may be re-refined to fibrillate the tobacco fibers. The refined tobacco pulp may then be passed through a Fourdrinier screen to produce a nonwoven web or paper. The web may be dried to a moisture content of 45-55%. The concentrated extract containing any aerosol-forming materials may then be added back to the web and dried to a moisture content of 8-10%. Optionally, an inert filter aid may be added to the pulp prior to web formation on a Fourdrinier screen.

[0156] In a second embodiment, cast sheet technology may be used to make a flat sheet. The cast sheet generally comprises a binder material, an inert filler, optionally one or more of two or more aerosol-forming agents, each of which is described herein, wood-derived fibers, and optionally a plant material, an active ingredient, and / or tobacco or tobacco-derived materials. For example, in some embodiments, a fiber material, one or more of two or more aerosol-forming materials disclosed herein, and a binder may be blended together to form a slurry, which may be cast onto a surface (e.g., a moving belt). The cast slurry may then undergo one or more drying and / or refining steps such that the result is a cast sheet of relatively constant thickness. Other examples of 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. 44,987,906 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 et al., and U.S. Pat. No. 6,216,706 to Kumar et al., the disclosures of which are incorporated herein by reference in their entireties. In some embodiments, the flat sheet may be further divided into cut lugs or strips for insertion into the substrate-containing segment of the aerosol delivery device. The cast sheet may also be collected into a rod or wound into a roll for insertion into the substrate-containing segment of the aerosol delivery device.

[0157] In a third embodiment, the substrate may be prepared by granule extrusion followed by spheronization or marumerization to produce round or oval beads or hair-like rods. Granule extrusion formulations are similar to those of cast sheet formulations, except that alternative or additional binders (e.g., cellulose derivatives) are used.

[0158] In a fourth embodiment, the substrate may be prepared by extrusion followed by cutting or sizing to provide substrate pieces of multiple sizes and / or shapes. The extrusion formulation is similar to that of the granular extrusion formulation, but with additional binder combinations (e.g., combinations of cellulose derivatives).

[0159] In any of the preceding embodiments, the entire amount of aerosol-forming material may be added prior to casting, extrusion, etc. to form the aerosol-generating members disclosed herein. Alternatively, or in addition, some 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 disposed into or onto a substrate material to form the aerosol-generating members disclosed herein).

[0160] Figure 3 shows a perspective schematic view of an aerosol generating member according to an exemplary embodiment of the present disclosure. In particular, Figure 3 shows an aerosol generating member 104 having a substrate portion 110 that includes a series of overlapping layers 130 of substrate 120 in sheet form. As noted above, in the illustrated embodiment, the substrate sheet 120 includes a film or layer as disclosed herein. In various embodiments, the term "overlapping layers" may also include bundled, crinkled, folded, and / or otherwise collected layers where the individual layers may not be distinct.

[0161] For example, Figure 4 shows a schematic cross-sectional view of a substrate portion of an aerosol generating member according to an exemplary embodiment of the present disclosure. In particular, Figure 4 shows a substrate portion 110 including a series of overlapping layers 130 of a substrate sheet 120. In the illustrated embodiment, at least a portion of the overlapping layers 130 is substantially surrounded about its outer surface by a first cover layer 132. In various embodiments, the composition of the first cover layer 132 can vary, but in the illustrated embodiment, the first cover layer 132 includes a combination of a fibrous material, an aerosol-forming material, and a binder material. Reference is made herein to the discussion of possible aerosol-forming and binder materials.

[0162] In various embodiments, the first cover layer 132 can be constructed by a casting process as described in US Pat. No. 5,697,385 to Seymour et al., which is incorporated herein by reference in its entirety.

[0163] In the illustrated embodiment, at least a portion of the overlap layer 130 and the first cover layer 132 are substantially surrounded about the outer surface by the second cover layer 134. Although the composition of the second cover layer 134 can vary, in the illustrated embodiment, the second cover layer 134 comprises a metal foil material, such as an aluminum foil material. In other embodiments, the second cover layer can comprise other materials, such as, but not limited to, a copper material, a tin material, a gold material, an alloy material, a ceramic material, or other thermally conductive amorphous carbon-based materials, and / or any combination thereof. The illustrated embodiment further includes a third cover layer 136 that substantially surrounds the overlap layer 130, the first cover layer 132, and the second cover layer 134 along the periphery of the outer surface. In the illustrated embodiment, the third cover layer 136 comprises a paper material, such as a conventional cigarette paper. In various embodiments, the paper material may include rag fibers, such as non-wood plant fibers, and may include flax, thyme, sisal, rice straw, and / or escarp grass fibers.

[0164] Aerosol-forming materials The aerosol generating member disclosed herein comprises a substrate impregnated with two or more aerosol forming materials, including a first aerosol forming material and a second aerosol forming material, each of which has a different boiling point, a different vapor pressure, or both. As used herein, reference to "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 changes to a vapor. When referring to boiling point herein, the pressure surrounding the liquid is standard atmospheric pressure (i.e., 760 mmHg).

[0165] Without wishing to be bound by theory, it is believed that the presence of two or more separate aerosol-forming materials, each with different volatility (e.g., boiling point), allows for greater control over aerosol formation when used in an aerosol-generating device. Controlling the volume and density of the aerosol and optimizing the timing of aerosol formation from an aerosol-generating device relative to the application of heat by utilizing two or more aerosol-forming materials can enhance the consumer experience versus 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 volatility can result in a more consistent delivery of aerosol throughout the use of a device or article that includes such a mixture of aerosol-generating materials. In particular, such a combination can provide a less variable amount of aerosol generated from one puff to the next during the use of an article or device described herein.

[0166] Furthermore, according to the present disclosure, it has been found 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 polyhydric alcohols, or mixtures of aerosol-forming materials containing polyhydric alcohols, increase the flexibility of the substrate. In contrast, certain other aerosol-forming materials, such as palmitic acid, in the absence of polyhydric alcohols, provided substrates that were brittle and difficult to process. Thus, the selection of aerosol-forming materials or appropriate combinations thereof can be utilized to avoid brittleness while providing consistent and long-lasting aerosol formation when loaded into a substrate and subjected to heating, as in the aerosol generating device disclosed herein.

[0167] In some embodiments, the aerosol-forming materials each have a different boiling point, and the boiling point is in the range of 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 first aerosol-forming material has a boiling point of 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 second aerosol-forming material has a boiling point of 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 point between the first and second aerosol-forming materials is in the range of about 50° C. to about 300° C., e.g., about 50° C., about 100° C., about 150° C., about 200° C., about 250° C., or about 300° C.

[0168] The first and second aerosol-forming materials may be present in various ratios, with either component predominating depending on the intended application. In some embodiments, the aerosol-forming materials are present in a weight ratio of about 100:1 to about 1:100, such as 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, of the first aerosol-forming material to the second aerosol-forming material. In some embodiments, the aerosol-forming materials are present in a weight ratio 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 of the first aerosol-forming material to the second aerosol-forming material. In some embodiments, the aerosol-forming materials are present in a weight ratio of about 3:1 to about 1:3 of the first aerosol-forming material to the second aerosol-forming material. 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.

[0169] In some embodiments, the substrate is further impregnated with at least one additional aerosol-forming material. The additional aerosol-forming material may have a boiling point in the same range as the first aerosol-forming material or the second aerosol-forming material, or may have a different boiling point range. For example, in one non-limiting embodiment, the first and second aerosol-forming materials may have a boiling point less than 350°C, and the boiling point of the additional aerosol-forming material may be greater than about 350°C. In another non-limiting embodiment, the first and second aerosol-forming materials may have a boiling point greater than about 175°C, and the boiling point of the additional aerosol-forming material may be less than about 175°C. In yet another non-limiting embodiment, the first and second aerosol-forming materials may have a boiling point between about 175°C and about 300°C, and the boiling point of the additional aerosol-forming material may be less than about 175°C or greater than about 300°C.

[0170] In some embodiments, each of the first and second aerosol-forming materials, and any additional aerosol-forming materials that may be present, is independently selected from the group consisting of water, polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, triacetin, waxes, cannabinoids, terpenes, and sugar alcohols.

[0171] In some embodiments, the aerosol-forming material comprises one or more polyhydric alcohols. Examples of polyhydric alcohols include glycerol, propylene glycol, and other glycols, such as 1,3-propanediol, diethylene glycol, triethylene glycol, and polyethylene glycol (e.g., PEG molecules having a weight average molecular weight range of about 200 to about 2,000 Da).

[0172] In some embodiments, the aerosol-forming material comprises one or more polysorbates. Examples of polysorbates include 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 intended desired effect, and different polysorbates provide different attributes due to their molecular size. For example, polysorbate molecules increase in size from polysorbate 20 to polysorbate 80. Using smaller sized polysorbate molecules produces less vapor volume but allows deeper lung penetration. This may be desirable when the user is in a public place and does not want to create a large plume of "smoke" (e.g., vapor). Conversely, larger polysorbate molecules may be used when a dense vapor capable of carrying the aromatic components of tobacco is desired. An additional advantage of using compounds of the polysorbate family is that polysorbates reduce the heat of vaporization of the mixture in which they are present.

[0173] 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).

[0174] 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 chain carboxylic acids. Fatty acids generally range from C4 to C 28 Non-limiting examples of short 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 includes palmitic acid.

[0175] 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 monolaurin and glycerol monostearate. Examples of triglycerides include triolein, tripalmitin, tristearate, glycerol tritylates, and glycerol trihexanoates.

[0176] In some embodiments, the aerosol-forming material comprises one or more waxes, examples of which include carnauba, beeswax, and candelilla, which are known to stabilize aerosol particles, increase palatability, or reduce throat irritation.

[0177] In some embodiments, the aerosol-forming material comprises one or more cannabinoids, hi some embodiments, the cannabinoids comprise cannabidiol (CBD), tetrahydrocannabinol (THC), or a combination thereof.

[0178] 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 biosynthetically from isopentenyl pyrophosphate. Non-limiting examples of terpenes include limonene, pinene, farnesene, and cembrene.

[0179] 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 also act as flavor enhancers for certain flavor compounds, such as menthol and other volatiles, and can generally improve the mouthfeel, texture, throat feel, and other sensory properties of the resulting aerosol.

[0180] In some embodiments, at least one of the first aerosol-forming material and the second aerosol-forming material is a polyhydric alcohol. In some embodiments, both the first aerosol-forming material and the second aerosol-forming material are polyhydric alcohols. In some embodiments, the polyhydric alcohol is glycerol and propylene glycol. The glycerol and propylene glycol may be present in various ratios, with either component predominating depending on the intended application, as disclosed hereinabove. For example, in some embodiments, the glycerol and propylene glycol are present in a weight ratio of about 3:1 to about 1:3. In some embodiments, the glycerol and 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, the glycerol and propylene glycol are present in a weight ratio of about 1:1.

[0181] In some embodiments, the substrate is further impregnated with at least one additional aerosol-forming agent. In some embodiments, the at least one additional aerosol-forming agent is selected from the group consisting of water, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, triacetin, sugar alcohols, cannabinoids, terpenes, and combinations thereof, each of which is described herein. In some embodiments, the first aerosol-forming material is glycerol, the second aerosol-forming material is propylene glycol, and the at least one additional aerosol-forming agent is water. In some embodiments, the first aerosol-forming material is glycerol, the second aerosol-forming material is 1,3-propanediol, and the at least one additional aerosol-forming material is water. In some embodiments, the first aerosol-forming material is glycerol, the second aerosol-forming material is propylene glycol, and the at least one additional aerosol-forming material is polysorbates. In some embodiments, the first aerosol forming material is glycerol, the second aerosol forming material is a sugar alcohol, and the at least one further additional aerosol forming agent is water.

[0182] In some embodiments, the substrate comprises a first aerosol-forming material selected from the group consisting of glycerol, propylene glycol, 1,3-propanediol, 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-propanediol, triethylene glycol, polyethylene glycol, triacetin, waxes, cannabinoids, terpenes, and sugar alcohols; and is impregnated with two or more aerosol-forming materials, wherein the first aerosol-forming material and the second aerosol-forming material each have a different boiling point, a different vapor pressure, or both.

[0183] In some embodiments, the first aerosol forming material is glycerol.In some embodiments, the first aerosol forming material is 1,3-propanediol, triethylene glycol, propylene glycol, or triacetin.

[0184] In some embodiments, the second aerosol forming material is 1,3-propanediol, 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.

[0185] In some embodiments, the first aerosol forming material is glycerol and the second aerosol forming material is 1,3-propanediol, triethylene glycol, palmitic acid, or triacetin.

[0186] In some embodiments, the first aerosol forming material is 1,3-propanediol, triethylene glycol, propylene glycol, or triacetin, and the second aerosol forming material is palmitic acid, polyethylene glycol 400, sorbitan stearate, or polysorbate 80.

[0187] In some embodiments, the first aerosol-forming material is glycerol and the second aerosol-forming material is palmitic acid. In some embodiments, the glycerol and palmitic acid are present in a weight ratio of about 100:1 to about 1:100, such as 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 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 aerosol forming agents listed, including but not limited to, 1,3-propanediol, triethylene glycol, triacetin, polyethylene glycol, or polysorbate 60.

[0188] In some embodiments, the substrate is impregnated with three aerosol forming agents. The ratio of the three aerosol forming materials may vary. Thus, any one of the three aerosol forming agents may 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, one aerosol forming agent is present in greater amounts relative to the other two aerosol forming agents. In certain embodiments, the three aerosol forming agents are present in a weight ratio of 1:1.5:1.5.

[0189] In some embodiments, the substrate is impregnated with a third aerosol-forming material selected from the group consisting of glycerol, palmitic acid, and 1,3-propanediol, triethylene glycol, propylene glycol, triacetin, polyethylene glycol 400, sorbitan tristearate, and polysorbate 80.

[0190] In some embodiments, the substrate is impregnated with glycerol, palmitic acid, and 1,3-propanediol, hi some embodiments, the glycerol, palmitic acid, and 1,3-propanediol are present in a weight ratio of 1:1.5:1.5.

[0191] In some embodiments, the substrate is impregnated with glycerol, palmitic acid, and triethylene glycol, hi some embodiments, the substrate is impregnated with glycerol, palmitic acid, and triethylene glycol in a weight ratio of 1:1.5:1.5.

[0192] In some embodiments, the substrate is impregnated with glycerol, palmitic acid, and propylene glycol, hi some embodiments, the substrate is impregnated with glycerol, palmitic acid, and propylene glycol in a weight ratio of 1:1.5:1.5.

[0193] In some embodiments, the substrate is impregnated with glycerol, palmitic acid, and triacetin, hi some embodiments, the substrate is impregnated with glycerol, palmitic acid, and triacetin in a weight ratio of 1:1.5:1.5.

[0194] 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.

[0195] In some embodiments, the substrate is impregnated with glycerol, palmitic acid, and sorbitan tristearate, hi some embodiments, the substrate is impregnated with glycerol, palmitic acid, and sorbitan tristearate in a weight ratio of 1:1.5:1.5.

[0196] 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.

[0197] In some embodiments, the substrate is impregnated with four aerosol forming agents. The ratio of the four aerosol forming materials may vary. In certain embodiments, the four aerosol forming agents are present in a weight ratio of 2:1:1:0.5.

[0198] In some embodiments, the substrate is impregnated with glycerol, palmitic acid, 1,3 propanediol, and triacetin, hi some embodiments, the substrate is impregnated with glycerol, palmitic acid, 1,3 propanediol, and triacetin in a weight ratio of 1:0.5:2:1.

[0199] In some embodiments, the substrate is loaded (e.g., incorporated or impregnated) with the aerosol-forming material described herein. The amount of aerosol-forming material incorporated (loaded) into the substrate is such that the aerosol-generating member provides acceptable sensory and desirable performance characteristics. For example, it is highly preferred that a sufficient amount of aerosol-forming material is used to generate a visible mainstream aerosol that resembles in many respects the appearance of tobacco smoke. The amount of forming material in the aerosol-generating member (e.g., impregnated substrate) may depend on factors such as the number of puffs desired per aerosol-generating member.

[0200] In some embodiments, the substrate is impregnated with at least about 5%, at least about 10%, at least about 15%, at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, or at least about 60% by weight of aerosol-forming material, based on the total weight of the impregnated substrate. Examples of ranges of total aerosol-forming material include from about 5 to about 60%, from about 10 to about 50%, or from about 20 to about 40%, such as from about 15% to about 55%, from about 15% to about 30%, or from about 15% to about 25%, based on the total weight of the impregnated substrate. Methods of loading an aerosol-forming material 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 by reference in their entireties herein.

[0201] In various embodiments, loading the substrate with the aerosol-forming material is accomplished by impregnating the substrate with the aerosol-forming material during preparation of the substrate material, after formation, or both. For example, in some embodiments, a first aerosol-forming material (e.g., propylene glycol) is added to the substrate forming slurry, e.g., during sheet making, and a second forming material (e.g., glycol) is added (e.g., by spraying) to the sheet as a top dressing to form the impregnated substrate (i.e., aerosol-generating member). In other embodiments, the first aerosol-forming material and the second aerosol-forming material are both added to the substrate forming slurry. In some embodiments, additional aerosol-forming material may be impregnated into the substrate, either in the substrate forming slurry or as a top dressing. As will be appreciated by those skilled in the art, multiple permutations of methods for loading the substrate with the aerosol-forming material are possible, depending on the particular substrate material, morphology, etc. Thus, such modifications are contemplated herein.

[0202] In some embodiments, the substrate is further impregnated with an active ingredient, a flavoring agent, or a combination thereof, each of which is further described herein below.

[0203] Active ingredient In certain embodiments, the substrate is further impregnated with one or more active ingredients. The active ingredients may be components of the aerosol-forming material or may be impregnated separately. Impregnation may occur during preparation of the substrate material, after substrate formation, or both.

[0204] As used herein, "active ingredient" refers to one or more substances belonging to any of the following categories: APIs (active pharmaceutical substances), food additives, natural drugs, and substances of natural origin that may have an effect on humans. Examples of active ingredients include any ingredient 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, cure, mitigation, treatment, or prevention of disease, or ingredients that affect the structure or any function of the human body (e.g., provide a stimulating effect on the central nervous system, an energizing effect, an antipyretic or analgesic effect, or an effect that is otherwise beneficial to the body). In some embodiments, the active ingredient may be of the type commonly referred to as a dietary supplement, nutraceutical, "botanical compound," or "functional food." These types of additives may be defined in the art as encompassing substances, typically available from naturally occurring sources (e.g., plant materials), that provide one or more beneficial biological effects (e.g., health promotion, disease prevention, or other medicinal properties), but are not classified or regulated as drugs.

[0205] Non-limiting examples of active ingredients include those in the categories of synthetic organic compounds, proteins and peptides, polysaccharides and other sugars, lipids, inorganic compounds, and nucleic acid sequences that have therapeutic, prophylactic, or diagnostic utility. Non-limiting examples of active ingredients include those in the categories of botanical ingredients, stimulants (e.g., caffeine and guarana), amino acids (e.g., taurine, theanine, phenylalanine, tyrosine, and tryptophan), and / or pharmaceutical, nutraceutical, and medicinal ingredients (e.g., vitamins, e.g., B6, B12, and C), and cannabinoids, e.g., tetrahydrocannabinol (THC) and cannabidiol (CBD)), antioxidants, and nicotine ingredients. The specific choice of active ingredient will depend on the desired flavor, texture, and desired properties of the particular product.

[0206] The specific percentage of active ingredients present will vary depending on the desired characteristics of the particular product. Typically, the active ingredient or combination thereof is present at a total concentration of at least about 0.001% by weight of the composition, for example, in the range of about 0.001% to about 20%. In some embodiments, the active ingredient or combination of active ingredients is present at a concentration of about 0.1% (w / w) to about 10% by weight, for example, about 0.5% (w / w) to about 10% by weight, 1% to about 10% by weight, about 1% to about 5% by weight, based on the total weight of the composition. In some embodiments, the active ingredient or combination of active ingredients is present in an amount of about 0.001%, about 0.01%, about 0.1%, or from about 1% to about 20% by weight, based on the total weight of the composition, for example, about 0.001%, about 0.002%, about 0.003%, about 0.004%, about 0.005%, about 0.006%, about 0.007%, about 0.008%, about 0.009%, about 0.01%, about 0.02%, about 0.03%, about 0.04%, about 0.05%, about 0.0 The active ingredient is preferably present in a concentration of about 0.06%, about 0.07%, about 0.08%, about 0.09%, about 0.1%, about 0.2%, about 0.3%, about 0.4%, about 0.5%, about 0.6%, about 0.7%, about 0.8%, or about 0.9% to about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about 10%, about 11%, about 12%, about 13%, about 14%, about 15%, about 16%, about 17%, about 18%, about 19%, or about 20% by weight. Further suitable ranges for certain active ingredients are provided herein below.

[0207] plant matter In some embodiments, the active ingredient comprises one or more non-tobacco botanical materials. As used herein, the term "botanical ingredient" or "botanical material" refers to any plant or fungal-derived material, including plant material in its natural form and plant material derived from a natural plant material, such as an extract or isolate from the plant material, or processed plant material (e.g., plant material that has been subjected to heat treatment, fermentation, or other treatment processes that can change the chemical properties of the material). For purposes of this disclosure, "botanical material" includes, but is not limited to, "herbal material." "Herbal material" refers to seed-producing plants (e.g., tea or tisane) that do not develop persistent woody tissue and are often valued for their medicinal or sensory properties. Reference to plant material as "non-tobacco" is intended to exclude tobacco material (i.e., does not include Nicotiana species). Botanical materials useful in this disclosure may include, but are not limited to, any of the compounds and sources described herein, as well as mixtures thereof. Certain botanical materials of this type are sometimes called dietary supplements, nutraceuticals, "phytocompounds" or "functional foods."

[0208] Non-limiting examples of botanical 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, beetroot, wild bergamot, black pepper, blueberry, borage seed oil, burdock, cacao, calamus root, catnip, catuaba, cayenne pepper, Centella asiatica, chaga mushroom, bupleurum frondosa, chamomile, cherry blossom, chervil, chlorophyll, cinnamon, dark chocolate, citrus, cocoa, comfrey leaf and root, ginkgo biloba, and others. biloba), carrots, goji berries, grapeseed, 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, carrots (e.g., Panax ginseng), goldenseal, green tea, grapefruit, Griffonia simplicifolia simplicifolia, guarana, centella, hawthorn, thyme, hibiscus flower, honeybush, hops, jasmine, gynostemma, Kaempferia parviflora (Thai ginseng), kava, lavender, lemon balm, lemongrass, licorice, yamabushitake mushroom, lutein, maca, matcha, Nardostachys chinensis, marjoram, milk thistle, mint (mantle), oolong tea, orange, oregano, papaya, pennyroyal, peppermint, potato peel, primrose, quercetin, red clover, resveratrol, Rhizoma gastrosiegastrodiae, Rhodiola rosea, Rooibos, Rooibos (red or green), Rose essential oil, Rose hips, Rosemary, Sage, Clary sage, Savory, Saw palmetto, Sceletium tortuosum, Schisandra chinensis, Silybum marianum, Skullcap, Spearmint, Japanese pepper, Spirulina, Slippery elm bark, Sorghum bran high tannin, Sorghum grain high tannin, St. John's wort, Sumac bran, Terpenes, Thyme, Tisane, Turmeric, Turnera aphrodisiaca, Bearberry, Valerian, Viola odorata, White mulberry, Wild yam root, Wintergreen, Withania somnifera somnifera), yacon root, yellow dock, yerba mate, and yerba santa, When present, the plant material is typically in a concentration of about 0.01% w / w to about 10% by weight based on the total weight of the composition, such as about 0.01% w / w, 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.

[0209] Nicotine content In some embodiments, the active ingredient comprises a nicotine component. By "nicotine component" is meant nicotine in any suitable form (e.g., free base or salt) to provide systemic absorption of at least a portion of the nicotine present. The source of nicotine may vary, and may be natural or synthetic. Most preferably, nicotine occurs naturally and is obtained as an extract of Nicotiana species (e.g., tobacco). Nicotine may have the enantiomeric forms 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 a form that is essentially all S(-)-nicotine) or a racemic mixture composed primarily or predominantly of S(-)-nicotine (e.g., a mixture composed of about 95 parts by weight of S(-)-nicotine and about 5 parts by weight of R(+)-nicotine). Most preferably, nicotine is used in a substantially pure or essentially pure form. Highly preferred nicotine employed has a purity of greater than about 95 percent, more preferably greater than about 98 percent, and most preferably greater than about 99 percent, on a weight basis.

[0210] Typically, the nicotine component is selected from the group consisting of nicotine free base and nicotine salts. In some embodiments, the nicotine is in free base form. The 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 can include a nicotine component. In various embodiments, the impregnated substrate can be free of a nicotine component. In some embodiments, the impregnated substrate can include a non-tobacco-derived nicotine component.

[0211] Typically, the nicotine component (calculated as the free base), when present, is at a concentration of at least about 0.001% by weight of the impregnated substrate, e.g., in the range of about 0.001% to about 10% by weight. In some embodiments, the nicotine component, calculated as the free base, is present in a concentration of about 0.1% w / w to about 10% w / w, e.g., about 0.1%, about 0.2%, about 0.3%, about 0.4%, about 0.5%, about 0.6%, about 0.7%, about 0.8%, or about 0.9% to about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, or about 10% by weight, based on the total weight of the impregnated substrate. In some embodiments, the nicotine component is present in a concentration of about 0.1% w / w to about 3% w / w, calculated as the free base, based on the total weight of the impregnated substrate, e.g., about 0.1% to about 2.5% w / w, about 0.1% to about 2.0% w / w, about 0.1% to about 1.5% w / w, about 0.1% to about 1% w / w. These ranges may also apply to other active ingredients described herein.

[0212] In some embodiments, the substrate of the present disclosure may be characterized as being completely free or substantially free of nicotine components. "Substantially free of nicotine components" means that no nicotine has been intentionally added, except for trace amounts that may be naturally present, for example, in plant materials. For example, certain embodiments may be characterized as having less than 0.001% nicotine by weight, or less than 0.0001% by weight, or even 0% nicotine by weight, calculated as free base.

[0213] Cannabinoids In some embodiments, the active ingredient comprises one or more cannabinoids. The term "cannabinoid" as used herein refers to a diverse class of natural or synthetic compounds that act on intracellular cannabinoid receptors (e.g., CB1 and CB2) to alter the release of neurotransmitters in the brain. Cannabinoids are cyclic molecules that exhibit certain properties, such as the ability to easily cross the blood-brain barrier. Cannabinoids may occur naturally from plants such as cannabis (phytocannabinoids), from animals (endocannabinoids), or may be artificially produced (synthetic cannabinoids). Cannabis species express at least 85 different phytocannabinoids, which include cannabigerol, cannabichromene, cannabidiol, tetrahydrocannabinol, cannabinol and cannabinodiol, as well as other cannabinoids such as cannabigerol (CBG), cannabichromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol (CBN) and cannabinodiol (CBDL), cannabicyclo Cannabinol is divided into subclasses including cannabinol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabinerolic acid, cannabidiolic acid (CBDA), cannabinol propyl variant (CBNV), cannabiditriol (CBO), tetrahydrocannabinolic acid (THCA), and tetrahydrocannabivarinic acid (THCV A).

[0214] In some embodiments, the cannabinoid is selected from the group consisting of cannabigerol (CBG), cannabichromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol (CBN) and cannabinodiol (CBDL), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabinerolic acid, cannabidiolic acid (CBDA), cannabinol propyl variant (CBNV), cannabiditriol (CBO), tetrahydrocannabinolic acid (THCA), tetrahydrocannabivarinic acid (THCV A), and mixtures thereof. In some embodiments, the cannabinoid comprises at least tetrahydrocannabinol (THC). In some embodiments, the cannabinoid is tetrahydrocannabinol (THC). In some embodiments, the cannabinoid comprises at least cannabidiol (CBD). In some embodiments, the cannabinoid is cannabidiol (CBD). In some embodiments, the CBD is synthetic CBD. In particular, CBD has a logP value of about 6.5, making it insoluble in aqueous environments (e.g., saliva).

[0215] In some embodiments, the cannabinoid (e.g., CBD) is added to the substrate in the form of an isolate, which is an extract from a plant, such as Cannabis, in which the active material in question (in this case the cannabinoid, e.g., CBD) is present in a high degree of purity, for example greater than 95%, greater than 96%, greater than 97%, greater than 98%, or about 99% pure.

[0216] In some embodiments the cannabinoid is a high purity isolate of CBD and the amount of any other cannabinoids in the substrate is about 1% or less by weight of the substrate, such as about 0.5% or less by weight of the substrate, such as about 0.1% or less by weight of the substrate, for example about 0.01% or less by weight of the substrate.

[0217] The selection of cannabinoids and the specific percentages thereof that may be present in the disclosed substrates will vary depending on the desired properties of the substrate.

[0218] In some embodiments, the cannabinoid (such as CBD) is present in the substrate at a concentration of at least about 0.001% by weight of the substrate, for example at a concentration ranging from about 0.001% to about 2% by weight of the substrate. In some embodiments, the cannabinoid (such as CBD) is present in the substrate at a concentration of about 0.1% to about 1.5% by weight based on the total weight of the substrate. In some embodiments, the cannabinoid (such as CBD) is present in the substrate at a concentration of about 0.4% to about 1.5% by weight based on the total weight of the substrate.

[0219] Alternatively, or in addition to cannabinoids, the active ingredient may include cannabimimetics, which are a class of compounds derived from plants other than cannabis that exert biological effects on the endocannabinoid system similar to cannabinoids.Examples include yangonin, alpha-amyrin or beta-amyrin (also classified as terpenes), cyanidin, curcumin (turmeric), catechin, quercetin, salvinorin A, N-acylethanolamines, and N-alkylamide lipids.Such compounds may be used in the same amounts and ratios as those described herein for cannabinoids.

[0220] Terpenes Active ingredients suitable for use in the present disclosure may also be classified as terpenes, many of which are associated with biological effects such as a calming effect. Terpenes have the general formula (C5H8): nIt is understood that the terpene has the formula: and includes monoterpenes, sesquiterpenes, and diterpenes. Terpenes can be acyclic, monocyclic, or bicyclic in structure. Some terpenes, when used in combination with cannabinoids or cannabimimetics, produce an entourage effect. Examples include beta-caryophyllene, linalool, limonene, beta-citronellol, linalyl acetate, pinene (alpha or beta), geraniol, carvone, eucalyptol, menthone, iso-menthone, piperitone, myrcene, beta-bourbonene, and germacrene, which can be used alone or in combination.

[0221] In some embodiments, the terpene is derivable from a phytocannabinoid-producing plant, such as a plant from the species Cannabis sativa, such as Taima. Suitable terpenes in this regard include so-called "C10" terpenes, which are those terpenes that contain 10 carbon atoms, and so-called "C15" terpenes, which are those terpenes that contain 15 carbon atoms. In some embodiments, the active ingredient comprises a plurality of terpenes. For example, the active ingredient may comprise 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more terpenes, as defined herein. In some embodiments, the terpene is selected from pinene (alpha and beta), geraniol, linalool, limonene, carvone, eucalyptol, menthone, iso-menthone, piperitone, myrcene, beta-bourbonene, germacrene, and mixtures thereof.

[0222] Tobacco ingredients In some embodiments, the active ingredient comprises a tobacco component (e.g., a tobacco extract). In various embodiments, the tobacco material may be processed to extract soluble components of the tobacco material. As used herein, "tobacco extract" refers to an isolated component of the tobacco material that is extracted from the solid tobacco pulp by a solvent that contacts the tobacco material in an extraction process. Various extraction techniques of tobacco materials may be used to provide tobacco extracts and tobacco solid materials. See, for example, the extraction process described in U.S. Patent Application Publication No. 2011 / 0247640 to Beeson et al., which is incorporated herein by reference.Other exemplary techniques for extracting tobacco components include U.S. Pat. Nos. 4,144,895 to Fiore, 4,150,677 to Osborne, Jr. et al., 4,267,847 to Reid, 4,289,147 to Wildman et al., 4,351,346 to Brummer et al., 4,359,059 to Brummer et al., 4,506,682 to Muller et al., 4,589,428 to Keritsis, 4,589,428 to Soga, all of which are incorporated herein by reference. No. 4,605,016 to Poulose et al., No. 4,716,911 to Niven, Jr. et al., No. 4,727,889 to Bernasek et al., No. 4,887,618 to Bernasek et al., No. 4,941,484 to Clapp et al., No. 4,967,771 to Fagg et al., No. 4,986,286 to Roberts et al., No. 5,005,593 to Fagg et al., No. 5,018,540 to Grubbs et al., No. 5,060,669 to White et al., and No. 5,065,775 to Fagg; No. 5,074,319 to White et al., No. 5,099,862 to White et al., No. 5,121,757 to White et al., No. 5,131,414 to Fagg; No. 5,131,415 to Munoz et al., No. 5,148,819 to Fagg; No. 5,197,494 to Kramer, No. 5,230,354 to Smith et al., No. 5,234,008 to Fagg, No. 5,243,999 to Smith, No. 5,301,694 to Raymond et al., No. 5,318,050 to Gonzalez-Parra et al., No. 5,343,879 to Teague, No. 5,350,000 to Newton ... No. 5,360,022 to Clapp et al., No. 5,435,325 to Brinkley et al., No. 5,445,169 to Lauterbach, 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.

[0223] Typical inclusion ranges of tobacco components may vary depending on the nature and type of tobacco material and the intended use of the aerosol-generating components. In some embodiments, products of the present disclosure may be characterized as being completely free or substantially free of tobacco components (other than purified nicotine as an active ingredient). For example, certain embodiments may be characterized as having less than 1% by weight, or less than 0.5% by weight, or less than 0.1% by weight, less than 0.01% by weight, or even 0% by weight of tobacco components.

[0224] Flavoring agents As mentioned above, the impregnated substrate may also include a flavoring agent. The active ingredient may be a part of the aerosol-forming material or may be impregnated separately. Impregnation may be performed during preparation of the substrate material, after substrate formation, or both. As used herein, reference to a "flavoring agent" refers to a compound or agent that can be aerosolized and delivered to a user and that provides a sensory experience in terms of taste and / or aroma. Flavoring agents may be natural or synthetic, and the flavor characteristics imparted thereby may be described as, without limitation, fresh, sweet, herbal, confectionery, floral, fruity, or spicy. Some examples of flavoring agents 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 hips, yerba mate, guayusa, honeybush, rooibos, yerba santa, bacopa monnieri, ginkgo biloba, withania somnifera, cinnamon, sandalwood, jasmine, cascarilla, cocoa, licorice, trigeminal sensate, terpene, and any combination thereof. As used herein, "trigeminal sensate" refers to a flavoring agent that acts on the trigeminal nerve to produce sensations such as heating, cooling, and tingling. Non-limiting examples of trigeminal sensate flavoring agents include capsaicin, citric acid, menthol, oleander, erythritol, and cubebol. Further non-limiting examples include flavorings and flavor packages of the type and characteristics conventionally used in cigarette, cigar, and pipe tobacco flavorings. See also Leffingwell et al., Tobacco Flavoring for Smoking Products, R. J. Reynolds Tobacco Company (1972), incorporated herein by reference. Flavoring agents may include members such as terpenes, terpenoids, aldehydes, ketones, esters, and the like.Syrups such as high fructose corn syrup may also be used. Some examples of plant-derived compositions that may be suitable are described in U.S. Patent No. 9,107,453 and U.S. Patent Application Publication No. 2012 / 0152265, both to Dube et al., the disclosures of which are incorporated herein by reference in their entirety. The selection of such additional components is variable based on factors such as the sensory characteristics desired in the smoking article, their affinity for the substrate material, their solubility and other physicochemical properties. The present disclosure is intended to encompass any such additional components that are readily apparent to those skilled in the art of tobacco and tobacco-related or tobacco-derived products. See, for example, Gutcho, "Tobacco Flavoring Substances and Methods, Noyes Data Corp. (1972)" and Leffingwell et al., "Tobacco Flavoring for Smoking Products (1972)," the disclosures of which are incorporated herein by reference in their entirety. It should be noted that reference to flavoring agents should not be limited to any single flavoring agent listed above, and may in fact represent a combination of one or more flavoring agents. Additional flavors, flavorings, additives and other possible enhancing ingredients are described in US Patent Application Publication No. 15 / 707,461 to Phillips et al., which is incorporated herein by reference in its entirety.

[0225] The amount of flavoring agent present may vary and, when present, is generally less than about 30% or less than about 20% by weight of the impregnated substrate. For example, the flavoring agent may be present in an amount of about 0.1%, about 0.5%, about 1%, or about 5% to about 10%, about 20%, or about 30% by weight of the impregnated substrate.

[0226] Aerosol Delivery Device As described herein, in another aspect, there is provided an aerosol delivery device comprising an aerosol generating member as described herein; a heat source configured to heat an aerosol forming material impregnated in a substrate portion to form an aerosol; and an aerosol pathway extending from the aerosol generating member to a mouth end of the aerosol delivery device.

[0227] In some embodiments, the aerosol generating member and the control body may be provided together as a complete smoking article or drug delivery article, although these members may be provided separately. For example, the present disclosure also encompasses a disposable unit for use with a reusable smoking article or a reusable drug delivery article. In certain embodiments, such a disposable unit (which may be the aerosol generating member shown in the accompanying drawings) may comprise a substantially tubular shaped body having a heating end configured to engage with a reusable smoking article or drug delivery article, an opposing mouth end configured to allow the passage of an inhalable substance to a consumer, and a wall having an outer surface and an inner surface that defines an interior space. Various embodiments of the aerosol generating member (or cartridge) are described in U.S. Patent No. 9,078,473 to Worm et al., which is incorporated herein by reference in its entirety.

[0228] Although some of the figures described herein show the regulator and the aerosol generating member in an operative relationship, it is understood that the regulator and the aerosol generating member may exist as separate devices, and therefore any discussion provided elsewhere herein regarding combined members should be understood to apply to the regulator and the aerosol generating member as individual and separate members.

[0229] In another aspect, the present disclosure relates to a kit providing various components described herein. For example, the kit may include a controller having one or more aerosol generating components. The kit may further include a controller having one or more charging components. The kit may further include a controller with one or more batteries. The kit may further include a controller having one or more aerosol generating components and one or more charging components and / or one or more batteries. In further embodiments, the kit may include multiple aerosol generating components. The kit may further include multiple aerosol generating components and one or more batteries and / or one or more charging components. In the above embodiments, the aerosol generating components or the controller may be provided with a heating element contained therein. The kit of the present invention may further include a case (or other packaging, carrying, or storage member) that houses one or more additional kit components. The case may be a reusable rigid or flexible container. Additionally, the case may simply be a box or other packaging structure.

[0230] Figure 5 shows a perspective view of an aerosol-generating member according to another exemplary embodiment of the present disclosure, and Figure 6 shows a perspective view of the aerosol-generating member of Figure 5 with the outer wrap removed. In particular, Figure 5 shows the aerosol-generating member 200 including the outer wrap 202, and Figure 6 shows the aerosol-generating member 200 with the outer wrap 202 removed to reveal the other components of the aerosol-generating member 200. In the illustrated embodiment, the aerosol-generating member 200 of the illustrated embodiment comprises a heat source 204, a substrate portion 210, an intermediate member 208, and a filter 212. In the illustrated embodiment, both the intermediate member 208 and the filter 212 comprise a mouthpiece 214.

[0231] Although the aerosol delivery device and / or aerosol generating member according to the present disclosure may take various embodiments, as described in detail below, the use of the aerosol delivery device and / or aerosol generating member by a consumer is similarly within the scope of the present invention. The above description of the aerosol delivery device and / or aerosol generating member is applicable to the various embodiments described with minor modifications that will be apparent to those skilled in the art in light of the further disclosure provided herein. However, the description of use is not intended to limit the use of the article of the present disclosure, but is provided to meet all necessary requirements of the disclosure herein.

[0232] In various embodiments, the heat source 204 may be configured to generate heat upon ignition. In the illustrated embodiment, the heat source 204 has a generally cylindrical shape and includes a combustible fuel element incorporating a combustible carbon material. In other embodiments, the heat source 204 may have a different shape, for example, a prismatic shape having a triangular, cubic, or hexagonal cross section. Carbonaceous materials generally have a high carbon content. Preferred carbonaceous materials may be composed primarily of carbon and / or may typically have a carbon content of greater than about 60%, commonly greater than about 70%, often greater than about 80%, and often greater than about 90%, on a dry weight basis.

[0233] In some examples, the heat source 204 may incorporate elements other than combustible carbonaceous materials (e.g., tobacco components, such as powdered tobaccac or tobacco extract; flavorings; salts, such as sodium chloride, potassium chloride, and sodium carbonate; heat stable graphite fibers; iron oxide powder; glass filaments; powdered calcium carbonate; alumina granules; ammonia sources, such as ammonia salts; binders, such as guar gum, ammonium alginate, and sodium alginate; and / or phase change materials to reduce the temperature of the above heat sources). While the specific dimensions of applicable heat sources may vary, in some embodiments, the heat source 204 may have a length in the inclusive range of about 7 mm to about 20 mm, and in some embodiments, may be about 17 mm, and an overall diameter in the inclusive range of about 3 mm to about 8 mm, and in some embodiments, may be about 4.8 mm (and in some embodiments, about 7 mm). In other embodiments, the heat source can be constructed in a variety of ways, but in the illustrated embodiment, the heat source 204 is extruded or compounded using ground or powdered carbonaceous material, with a dry weight basis of approximately 0.5 g / cm 3 Larger, often around 0.7 g / cm 3 , often around 1 g / cm 3It has a greater density. 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 in their entireties. In various embodiments, the heat source can have a variety of forms, including, for example, a substantially solid cylindrical shape or a hollow cylindrical (e.g., tubular) shape, and the heat source 204 in the illustrated embodiment comprises an extruded monolithic carbonaceous material that is generally cylindrical but has 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, and in particular 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 disposed in or within the heat source. Some examples of heat transfer members are described in U.S. Patent Application No. 15 / 923,735, filed March 16, 2018, and entitled Smoking Article with Heat Transfer Component, which is incorporated by reference in its entirety.

[0234] In the illustrated embodiment, the grooves 216 of the heat source 204 are substantially equal in width and depth and substantially evenly distributed around the circumference of the heat source (204), although other embodiments may include two grooves and still other embodiments may include a single groove. Still other embodiments may not include any grooves at all. Additional embodiments may include grooves that may be unequal in width and / or depth and may be unevenly spaced around the circumference of the heat source. In still other embodiments, the heat source may include grooves and / or slits that extend longitudinally from a first end to an opposing second end of the extruded monolithic carbonaceous material. In some embodiments, the heat source may include an expanded carbon monolith formed during 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. Thus, some embodiments may provide advantages with respect to a reduced time required to ignite the heat source. In some other embodiments, the heat source is co-extruded with an insulating layer (not shown), thereby reducing manufacturing time and costs. Other embodiments of the fuel element include carbon fiber of the type described in U.S. Pat. No. 4,922,901 to Brooks et al., or other heat source embodiments disclosed in U.S. Patent Application Publication No. 2009 / 0044818 to Takeuchi et al., which are incorporated herein by reference in their entireties.

[0235] In general, the heat source is positioned sufficiently close to an aerosol generating member (e.g., substrate portion) having one or more aerosolizable elements such that an aerosol (and any flavorings, medicaments, etc. similarly provided for delivery to the user) formed / volatilized by application of heat from the heat source to the aerosolizable elements can be delivered to the user through the mouthpiece. That is, when the heat source heats the substrate portion, an aerosol is formed, released, or generated in a physical form suitable for inhalation by the consumer. It should be noted that the foregoing terms are meant to include references to release, releasing, releases, or released interchangeably to include form or generate, forming or generating, forms or generates, and formed or generated. Specifically, the inhalable substance is released in the form of a vapor or an aerosol or a mixture thereof. Additionally, the selection of the various aerosol delivery device components will be appreciated in light of commercially available electronic aerosol delivery devices, such as the representative products listed in the Background section of this disclosure.

[0236] 5 and 6, the outer wrap 202 may be provided to engage or otherwise join at least a portion of the heat source 204 with at least a portion of the substrate portion 210 and the mouthpiece 214. In various embodiments, the outer wrap 202 is configured to be held in the wrapped position in any manner, such as via adhesive, fasteners, or the like, to allow the outer wrap 202 to remain in the wrapped position. Alternatively, in some other embodiments, the outer wrap 202 may be configured to be removable as desired. For example, once the outer wrap 202 is held in the wrapped position, the outer wrap 202 may be removed from the heat source 204, the substrate portion 210, and / or the mouthpiece 214.

[0237] In some embodiments, in addition to the outer wrap 202, the aerosol delivery device may also include a liner configured to circumscribe at least a portion of the substrate portion 210 and the heat source 204. In other embodiments, the liner may circumscribe only a portion of the length of the substrate portion 210, while in some embodiments, the liner may circumscribe substantially the entire length of the substrate portion 210. In some embodiments, the outer wrap material 202 may include a liner. Thus, in some embodiments, the outer wrap material 202 and the liner may be separate materials that are provided together (e.g., bonded, fused, or otherwise joined together as a laminate). In other embodiments, the outer wrap 202 and the liner may be the same material. In either case, the liner may be configured to thermally regulate the conduction of heat generated by the ignited heat source 204 radially outward of the liner. Thus, in some embodiments, the liner may be constructed from a metal foil material, an alloy material, a ceramic material, or other thermally conductive amorphous carbon-based material, and / or an aluminum material. In some embodiments, a laminate may be included. In some embodiments, depending on the material of the outer wrap 202 and / or the liner, a thin insulating layer may be provided radially outward of the liner. Thus, the liner may in some aspects advantageously provide a method of engaging two or more separate components of the aerosol generating member 200 (e.g., the heat source 204, the substrate portion 210, and / or a portion of the mouthpiece 214) while facilitating heat transfer axially along the axial direction, but limiting heat conduction radially outward.

[0238] 5, the outer wrap 202 (and liner and substrate portion 210, if necessary) may include one or more openings to allow for the entrainment of air upon inhalation at the mouthpiece 214. In various embodiments, the size and number of these openings may vary based on the particular design requirements. In the illustrated embodiment, a plurality of openings 220 are located proximate the end of the substrate portion 210 closest to the heat source 204, and a plurality of separate cooling openings 221 are formed in the outer wrap 202 (and in some embodiments, the liner) in the region proximate the filter 212 of the mouthpiece 214. Other embodiments differ from the illustrated embodiment in that the openings 220 comprise a plurality of openings substantially evenly spaced around the outer surface of the aerosol generating member 200, and the openings 221 also comprise a plurality of openings substantially evenly spaced around the outer surface of the aerosol generating member 200. In various embodiments, multiple openings may be formed through the outer wrap 202 (and in some embodiments, the liner), but in the illustrated embodiment, the multiple openings 220 and multiple separate cooling openings 221 are formed via laser drilling.

[0239] Referring to FIG. 6, the aerosol generating member 200 of the illustrated embodiment includes an intermediate member 208 and at least one filter 212. It should be noted that in various embodiments, the intermediate member 208 or the filter 212, individually or together, can be considered the mouthpiece 214 of the aerosol generating member 200. Although in various embodiments, neither an intermediate member nor a filter need be included, in the illustrated embodiment, the intermediate member 208 includes a substantially rigid member that is substantially flexible along its longitudinal axis. In the illustrated embodiment, the intermediate member 208 includes a hollow tubular structure and is included to add structural integrity to the aerosol generating member 200 and to cool the generated aerosol. In some embodiments, the intermediate member 208 can be used as a container for collecting the aerosol. In various embodiments, such components can be constructed from any of a variety of materials and can include one or more adhesives. Exemplary materials include, but are not limited to, paper, paper layers, paperboard, plastic, cardboard, and / or composite materials. In the illustrated embodiment, the intermediate member 208 includes a hollow cylindrical element constructed from paper or a plastic material (e.g., ethyl acetate (EVA), or other polymeric materials such as polyethylene, polyester, silicone, etc., or ceramics (e.g., silicon carbide, alumina, etc.), or other acetate fibers), and the filter includes a packed rod or cylindrical disk constructed from a gas permeable material (e.g., cellulose acetate or fibers such as paper or rayon, or polyester fibers).

[0240] As mentioned above, in some embodiments, the mouthpiece 214 may include a filter 212 configured to pass aerosol in response to a draw applied to the mouthpiece 214. In various embodiments, the filter 212 is provided as a circular disk, in some aspects, radially and / or longitudinally disposed proximate the second end of the intermediate member 208. In this manner, upon drawing on the mouthpiece 214, the filter 212 receives the aerosol flowing through the intermediate member 208 of the aerosol generating member 200. In some embodiments, the filter 212 may include separate segments. For example, some embodiments provide a segment that provides filtering, a segment that provides a resistance to drawing, a hollow segment that provides space for the aerosol to cool, a segment that provides increased structural integrity, other filter segments, and any one or any combination of the above. In some embodiments, the filter 212 may additionally or alternatively include strands of tobacco-containing material, such as those described in U.S. Pat. No. 5,025,814 to Raker et al., which is incorporated herein by reference in its entirety.

[0241] In various embodiments, the size and shape of intermediate member 208 and / or filter 212 may vary, for example, the length of intermediate member 208 may be in the inclusive range of about 10 mm to about 30 mm, the diameter of intermediate member 208 may be in the inclusive range of about 3 mm to about 8 mm, the length of filter 212 may be in the inclusive range of about 10 mm to about 20 mm, and the diameter of filter 212 may be in the inclusive range of about 3 mm to about 8 mm. In the illustrated embodiment, intermediate member 208 has a length of about 20 mm and a diameter of about 4.8 mm (and in some embodiments, about 7 mm), and filter 212 has a length of about 15 mm and a diameter of about 4.8 mm (or in some embodiments, about 7 mm).

[0242] In various embodiments, ignition of the heat source 204 results in aerosolization of the aerosol-forming material associated with the substrate portion 210. Preferably, the elements of the substrate portion 210 do not thermally decompose (e.g., char, scorch, or burn) to any significant extent, and the aerosolized components are carried along in the airflow drawn through the aerosol-generating member 200, including the filter 212, into the user's mouth. In various embodiments, the mouthpiece 214 (e.g., the intermediate member 208 and / or the filter 212) is configured to pass the generated aerosol in response to a draw applied by a user to the mouthpiece 214. In some embodiments, the mouthpiece 214 can be fixedly engaged to the substrate portion 210. For example, adhesives, bonds, welding, and the like may be suitable for fixedly engaging the mouthpiece 214 to the substrate portion 210. In one example, the mouthpiece 214 is ultrasonically welded and sealed at the ends of the substrate portion 210.

[0243] Many modifications and other embodiments of the present disclosure will be contemplated by one skilled in the art to which this disclosure pertains having the benefit of the teachings set forth in the foregoing descriptions and the corresponding drawings. It is therefore to be understood that the present disclosure is not limited to the specific embodiments disclosed herein, but that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. EXAMPLES

[0244] Aspects of the present invention will be more fully illustrated by the following examples, which are provided to illustrate certain aspects of the disclosure and should not be construed as limiting the invention.

[0245] Example 1: Papermaking process preparation of heat-not-burn (HNB) aerosol former substrate Aerosol former substrate 1A (reference substrate) Tobacco (flakes and stems, 400 lb) was mixed with 10 times its weight in water and extracted in a counter extractor at 70°C for 1 hour. The contents of the extractor were then separated by centrifugation into a thin tobacco extract (3-4% w / v) and non-soluble tobacco solids. The thin extract was transferred to a vacuum evaporator and concentrated to 23% solids (w / v). Glycerol (75 lb) was added and the mixture was mixed thoroughly to obtain the final liquid composition. Pre-refined wood pulp (25 lb) was mixed with the tobacco solids and sufficient water was added to bring the mixture to 1% solids (w / v). The total batch weight was 500 lb. A disc refiner was used to refine the wood pulp-tobacco solids mixture to obtain fibrillated tobacco pulp. The fibrillated tobacco pulp was conveyed to a headbox and discharged on a Fourdrinier wire machine to obtain a wet web or base sheet. The base sheet was dried to a moisture content of 40-55%. The final liquid composition was returned to 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 leaflet pieces.

[0246] Aerosol-forming agent substrates 1Bi and 1Bii (substrates of the invention) Aerosol-forming Substrate 1Bi was prepared similarly to Substrate 1A, except that the wood pulp was removed and the glycerol was replaced with a 75 / 25 mixture by weight of glycerol and propylene glycol. For Aerosol-forming Substrate 1Bii, calcium carbonate (present as a filler and drainage aid) was mixed with half of the fibrillated tobacco pulp prior to forming a wet web. Total batch weight was 300 lb (150 lb for each substrate).

[0247] Aerosol-forming agent substrate 1C (substrate of the present invention) Aerosol-forming Substrate 1C was prepared similarly to Substrate 1A, except that the glycerol was replaced with a 50 / 50 mixture by weight of glycerol and propylene glycol. The total batch weight was 300 lb.

[0248] Aerosol-forming agent substrate 1D (substrate of the present invention) Aerosol former Base 1D was prepared similarly to Base 1A except glycerol was replaced with a 25 / 75 mixture by weight of glycerol and propylene glycol. Total batch weight was 300 lb. See Table 1.

[0249] Aerosol former substrate 1E (reference substrate) Aerosol-forming Substrate 1E was prepared similarly to Substrate 1B except glycerol was replaced with propylene glycol. Total batch weight was 300 lb. See Table 1.

[0250] [Table 1]

[0251] Example 2: Cast Sheet Preparation of HNB Aerosol Forming Agent Substrate Aerosol former substrate 2A (reference substrate) Sodium alginate (50 lb) was slowly added to water (1650 lb) and hydrated under vacuum for 30 minutes in a high shear mixing tank. In a separate mixing tank, calcium carbonate (250 lb) was slowly added to glycerol (100 lb) and tobacco extract powder (100 lb) and then gently mixed for 30 minutes to form a slurry. The hydrated alginate was then mixed with zero freeness pre-refined wood pulp and then transferred to the calcium carbonate slurry and then mixed for an additional 30 minutes under medium mixing speed and vacuum to obtain the final slurry. The final slurry was then cast onto a 22 inch wide stainless steel conveyor belt using a casting knife set at 1-3 mm gap opening. The cast material or film was then dried into a flat sheet by conveying the film through a 200 ft convection tunnel dryer containing multiple heating zones (80-100°C). The total batch weight was 500 lb. The flat sheet was wound onto a bobbin and vacuum sealed in a polyethylene bag to prevent moisture absorption and blocking during shipping. The bobbin was then unwound and the sheet cut into strips (25-20 cuts / in2).

[0252] Aerosol-forming agent substrate 2B (substrate of the present invention) Aerosol-forming Substrate 2B was prepared similarly to Substrate 2A, except that the glycerol was replaced with a 75 / 25 mixture by weight of glycerol and propylene glycol, and zero freeness pre-refined wood pulp was added to the hydrated alginate and mixed for 30 minutes before adding to the calcium carbonate slurry. The total batch weight was 500 lb. (See Table 2).

[0253] Aerosol-forming agent substrate 2C (substrate of the present invention) Aerosol-forming Substrate 2C was prepared similarly to Substrate 2A, except that the glycerol was replaced with a 50 / 50 mixture by weight of glycerol and propylene glycol. The total batch weight was 300 lb.

[0254] Aerosol-forming agent substrate 2D (substrate of the present invention) Aerosol-forming Substrate 2D was prepared similarly to Substrate 2A, except that the glycerol was replaced with a 25 / 75 mixture by weight of glycerol and propylene glycol. The total batch weight was 300 lb.

[0255] Aerosol former substrate 2E (reference substrate) Aerosol-forming Substrate 2E was prepared similarly to Substrate 2A except glycerol was replaced with propylene glycol. The total batch weight was 300 lb.

[0256] Aerosol former substrate 2F (reference substrate) Aerosol-forming substrate 2F was prepared similarly to substrate 2A, except that sodium alginate was replaced with ammonium alginate as the binder.

[0257] [Table 2]

[0258] Example 3: Preparation of Bead and Granular Rod HNB Aerosol-Forming Substrates Aerosol former substrate 3A (reference substrate) Measured amounts of calcium carbonate (35 lb) and pregelatinized rice starch (5 lb) were added to a FM 130 D Littleford model precision plow mixer. The contents were mixed at 100 rpm for 10 minutes, then glycerol (20 lb) was added and mixed for an additional 10 minutes at 100 rpm. The mixer was stopped and a pre-prepared slurry of carboxymethylcellulose ((CMC), prepared by hydrating carboxymethylcellulose (5 lb) with water (17 lb) in a vessel using a pitchfork propeller for 30 minutes) was added and then mixed at 100 rpm for 20 minutes. The contents of the plow mixer were dispensed and transferred to a MG-55-1 Fuji Paudel model multigrain extruder. The mass was extruded through a 2-3 mm domed screen die to obtain multigrain (hair-like) shaped rods. The rods were then transferred to a QJ-230T-2 Fuji Paudal model laboratory mulmerizer. The rods were reshaped into rounded or spheronized beads using a marumerizer rotating bowl. The beads were then transferred to a fluid bed agglomerator (Flo-Coater, Vector Inc.) and finally dried to 10% moisture with heated air at 60-70°C. A portion of the extruded rods was also transferred and then dried using a fluid bed agglomerator device. The total batch weight was 50 lb.

[0259] Aerosol-Forming Agent Substrate 3B (Substrate of the Invention) Aerosol-forming Substrate 3B was prepared similarly to Substrate 3A, except glycerol was replaced with a 75 / 25 mixture by weight of glycerol and propylene glycol. Total batch weight was 50 lb. See Table 3.

[0260] Aerosol-Forming Agent Substrate 3C (Substrate of the Invention) Aerosol-forming Substrate 3C was prepared similarly to Substrate 3A, except that the glycerol was replaced with a 50 / 50 mixture by weight of glycerol and propylene glycol. The total batch weight was 50 lb.

[0261] Aerosol-forming agent substrate 3D (substrate of the present invention) Aerosol-forming Substrate 3D was prepared similarly to Substrate 3A, except that the glycerol / propylene glycol ratio was a 25 / 75 mixture by weight. The total batch weight was 50 lb.

[0262] Aerosol former substrate 3E (reference substrate) Aerosol-forming Substrate 3E was prepared similarly to Substrate 3A except glycerol was replaced with propylene glycol. Total batch weight was 50 lb. See Table 3.

[0263] Aerosol former substrate 3F (reference substrate) Aerosol former Base 3F was prepared similar to Base 3A except that rice starch was replaced with finely ground tobacco. Total batch weight was 50 lbs.

[0264] [Table 3]

[0265] Example 4: Preparation of an extruded HNB aerosol former substrate Aerosol former substrate 4A (reference substrate) Hydroxypropyl methylcellulose (HPMC; 2.5 lb) and hydroxypropyl cellulose (HPC; 2.5 lb) were mixed with glycerol (25 lb) in a Hobart mixer for 20 minutes. The mixture was then added to calcium carbonate (10 lb), pregelatinized rice starch (30 lb) and tobacco powder (30 lb) in a FM 130 D Littleford model precision plow mixer and mixed at 100 rpm for 30 minutes. After 30 minutes, the contents of the plow mixer were transferred to a K-Tron hopper in-line with a ZSK-25 Coperion twin screw model extruder. The hopper contents were then fed into an extruder containing 11 barrel sections (27-100°C) operating at a screw speed of 75 rpm. Water (35 lb) was fed into the second barrel of the extruder to aid in kneading, mixing and plasticizing the dough. A variety of extrudate shapes were produced using shaped dies (flat sheet, solid rod, rod with a center hole or internal opening, rod with a grooved outer edge). With the exception of the flat sheet extrudate, the resulting extrudate was cut upon exiting the die and immediately dried to 10-12% moisture using an infrared tunnel dryer (Model Proj 0115 Glenroe Integrated Energy Delivery Systems). Total batch weight was 100 lb.

[0266] Aerosol-forming agent substrate 4B (substrate of the present invention) Aerosol-forming Substrate 4B was prepared similarly to Substrate 4A, except that the glycerol was replaced with a 50 / 50 mixture by weight of glycerol and propylene glycol. The total batch weight was 50 lb.

[0267] Aerosol-forming agent substrate 4C (substrate of the present invention) Aerosol former Base 4C was prepared similarly to Base 4B, except the glycerol / propylene glycol ratio was a 25 / 75 mixture by weight, rice starch, HPMC and HPC were reduced in amount, and liquid mint flavor was added to the glycerol / propylene glycol mixture to impart flavor to the formulation. Total batch weight was 50 lb.

[0268] [Table 4]

[0269] Example 5: DSC of aerosol-forming materials Several embodiments of liquid aerosol-forming materials and mixtures containing glycerol or propylene glycol (reference) and mixtures thereof with different ratios (invention) were prepared. The thermal properties of these embodiments were measured by differential scanning calorimetry (DSC). DSC measures the amount of energy absorbed (enthalpy) or heat required (heat of vaporization) and energy released (heat release) when an aerosol former changes phase (liquid to vapor) during heating. The results of these experiments (Table 5 and Figure 7) showed that less heat or energy was required to change the aerosol-forming material from liquid to aerosol (endotherm) when propylene glycol (PG) was mixed with glycerol (VG) at levels >50%. The latter shows that combining aerosol formers with different boiling points or vapor pressures can lead to aerosol formation over a wider temperature range compared to each of the individual components.

[0270] [Table 5]

[0271] Example 6: DSC of aerosol-generating components The thermal profiles of embodiments of the aerosol-generating components in the substrate matrix were measured by DSC. A similar trend in the decrease in endothermic enthalpy with increasing PG content in the liquid mixture was observed across the evaluated examples (Table 6). In general, the ratio of PG to glycerol (>50%) lowers the enthalpy or heat of vaporization in any matrix (paper, cast sheet or beaded product). The data in Table 6 also revealed that aerosol formation was affected by the matrix format, e.g., lower enthalpy for the beaded product.

[0272] [Table 6]

[0273] Example 7: Thermogravimetric analysis-mass spectroscopy (TGA / MS) ion curves for aerosol-generating components in a substrate matrix The ion curve profiles of embodiments of the aerosol-generating component in a substrate matrix were measured by TGA / MS. The substrate samples were heated from ambient temperature to 250° C. (1 min) and then held at 250° C. for 4 min. FIG. 8 (Ion current curve overlay of glycerol (M / Z 43); Paper Reconstituted Treatment Substrate) and FIG. 9 (Ion current curve overlay of glycerol (M / Z 43; Bead Substrate) showed a wider aerosolized glycerol ion curve distribution over time for the mixed glycerol-PG sample when compared to the glycerol or PG only counterparts. These observations demonstrated the advantage of using a mixture of two or more aerosol-forming materials with one aerosol-forming material over a period of time for aerosol formation.

[0274] Example 8: Thermogravimetric analysis on aerosol-forming materials. The weight change of nine aerosol-forming material samples when heated from room temperature to 260°C was studied using thermogravimetric analysis (TGA). Approximately 5-10 mg of each sample was weighed for TGA application. TGA testing was performed on a TA Instruments TGA 5500. The method used in this study applied a temperature program with a ramp of 500°C / min to reach 210°C, followed by a temperature jump to 260°C, to most efficiently increase the temperature to 260°C without overshoot. The heating procedure allowed the samples to be heated from room temperature to 260°C in 1 minute, then held isothermal for another 4 minutes, etc. Weight change was monitored from 0 to 1 minute as well as from 1 to 5 minutes. The tests were performed in triplicate. The weight loss average of the triplicate replicates was calculated and is presented in Table 7. The temperatures of the samples at 1 and 5 minutes are also reported in Table 7.

[0275] As shown, some test materials resisted volatilization during the first minute of heating, as indicated by relatively low weight loss during the first minute. In particular, glycerol, palmitic acid, PEG400, sorbitan tristearate, and polysorbate 80 all exhibited less than 50% weight loss during the first minute. This suggests that these compounds may be useful in mixtures with another additional aerosol-forming material that volatilizes more quickly. Conversely, 1,3-propanediol, triethylene glycol, propylene glycol, and triacetin all exhibited significantly higher volatility during the first minute. Thus, these compounds may be good candidates for mixing with the less volatile compounds mentioned above. Such combinations may result in consistent aerosol volumes during a series of puffs, with the more volatile aerosol-forming compounds forming a larger percentage of the early puffs and the less volatile compounds forming a larger percentage of the later puffs.

[0276] Furthermore, for the PEG 400, sorbitan tristearate, and polysorbate 80 samples, less than 50% of the samples were aerosolized after 5 minutes, suggesting that these compounds are well suited for aerosol devices operating at higher temperatures (e.g., approximately 280-300 °C).

[0277] [Table 7]

[0278] Example 9: Thermogravimetric analysis-mass spectroscopy (TGA / MS) on aerosol-forming material mixtures The release profiles of eight aerosol-forming material mixture samples from Table 8 were studied using TGA-MS. All tests were performed on a TA Instrument Discovery TGA 5500 instrument connected to a Discovery mass spectrometer. All tests were performed in high purity nitrogen. Tests were performed in duplicate for validation purposes.

[0279] Each sample containing two aerosol forming materials is shown in Table 8 in a 1:1 weight ratio. Approximately 2-4 mg of each sample was weighed into a tared aluminum pan for analysis. The samples were heated using a temperature program with a 50°C / min ramp to 210°C followed by a temperature jump to 260°C. The heating procedure allowed the sample to heat from room temperature to 260°C in 1 minute and then held isothermal for an additional 4 minutes. Ion fragments (according to the National Institute of Standards and Technology MS Spectral Reference) for each sample are listed in Table 8 and were monitored for each mixture sample using a peak jump recipe on the mass spectrometer with settings of Faraday 7.

[0280] [Table 8]

[0281] The overlay of TGA thermograms for all eight samples is presented in Figure 10, from which it was observed that the mixtures with glycerol lost all their weight before 0.75 minutes and the mixtures with palmitic acid continued to lose some amount of weight after 0.75 minutes. It was also observed from the TGA curves that all the samples tested were vaporized within 1 minute.

[0282] The ion current for the eight samples was smooth at a setting of 15 in the Trios software. Most of the aerosol-forming mixture samples were observed to occur in as little as one minute or less, except for the glycerol / propylene glycol, glycerol / triethylene glycol, and glycerol / 1,3-propanediol mixtures, which could be detected in approximately two minutes. From the initial TGA weight loss results, all weight losses were complete within one minute.

[0283] The foregoing data suggests that aerosol-forming material mixtures containing palmitic acid may be useful in providing more consistent aerosol volume delivery over time, leading to reduced puff-to-puff variability in smoking devices containing such mixtures.

[0284] Example 10: Thermogravimetric Analysis-Mass Spectroscopy (TGA / MS) Ion Curves for Aerosol-Generating Materials in Substrate Matrices Ten handsheet substrate samples containing various mixtures of aerosol forming agents were prepared according to the formulations provided in Table 9. The aerosol forming materials in each sample are provided in Table 10.

[0285] [Table 9]

[0286] The release profile of 10 handsheet samples was studied using TGA-MS. All tests were performed on a TA Instrument Discovery TGA 5500 instrument connected to a Discovery mass spectrometer. All tests were performed in high purity nitrogen. Tests were performed in duplicate for validation purposes.

[0287] Approximately 2-4 mg of each sample was weighed into a tared aluminum pan for analysis. The samples were heated using a temperature program with a 50°C / min ramp to 210°C followed by a temperature jump to 260°C. The heating procedure allowed the sample to heat from room temperature to 260°C in 1 minute and then held isothermal for an additional 4 minutes. Ion fragments (according to the National Institute of Standards and Technology MS Spectral Reference) for each sample are listed in Table 10 and were monitored for each mixture sample using a peak jump recipe on the mass spectrometer with settings of Faraday 7.

[0288] [Table 10]

[0289] The overlay of the TGA thermograms for all ten samples is shown in Figure 11. From the TGA overlay curves, it was observed that the samples lost most of their volatile moieties within 1 minute.

[0290] For mass spectroscopy, no ion current signal was observed for tested Samples A, B, C, F, I, and J, and only small signals were observed for Samples D, E, G, and H. The lack of signal or small signal for the alternative aerosol former samples may be due to loss of aerosol forming material during the drying process of the handsheet sample preparation process or prior to sample testing. Samples D, E, G, and F demonstrate longer aerosol lifetime than the other candidates shown in Table 10.

[0291] Example 11: Thermogravimetric Analysis-Mass Spectroscopy (TGA / MS) Ion Curves for Aerosol-Generating Materials in Substrate Matrices Eight handsheet substrate samples containing various mixtures of aerosol forming agents were prepared in a matrix format according to the formulations presented in Table 11, all weight percentages are dry weight.

[0292] Carboxymethylcellulose (CMC2500) is slowly added to water and hydrated in a high shear mixing tank for 30 minutes under vacuum. In a separate mixing tank, finely milled tobacco is slowly added to the aerosol-forming material(s) and water, then gently mixed for 30 minutes to form a tobacco-water slurry. The hydrated CMC2500 is then mixed with pre-refined zero freeness wood pulp and transferred to a tobacco-water slurry tank, then mixed under moderate mixing speed and vacuum for an additional 30 minutes to obtain the final slurry.

[0293] The final slurry is then cast onto a 22 inch wide stainless steel conveyor belt using a casting knife set at a gap opening of 1-3 mm. The cast material (film) is dried into a substantially flat sheet by transporting the film through a 200 foot convection tunnel dryer containing multiple heating zones (80-100°C). The flat sheet is wound onto a bobbin and vacuum sealed in a polyethylene bag to prevent moisture absorption and blocking during transport. The bobbin is then unwound and the sheet is cut into strips (25-20 cuts per square inch).

[0294] The release profiles of eight handsheet samples were studied following the procedure of Example 10.

[0295] [Table 11]

[0296] Example 12: Thermogravimetric analysis of combinations of aerosol-generating materials A set of 16 combinations of aerosol-forming materials were prepared and studied by TGA using the procedure of Example 9. The matrices are presented in Table 12. Each of the aerosol-forming materials identified exists in a binary mixture shown in a 1:1 weight ratio. The release profiles of the 16 samples are studied following the procedure of Example 8.

[0297] [Table 12]

[0298] Example 13: Thermogravimetric analysis of aerosol-generating materials in a substrate matrix Six handsheet substrate samples containing various mixtures of aerosol forming agents were prepared according to the formulations presented in Table 9. The aerosol forming materials in each sample are presented in Table 13, and all weight percentages are dry weight. The release profiles of the six handsheet samples were studied using TGA. All tests were performed on a TA Instrument Discovery TGA 5500 instrument. The tests were repeated three times for validation purposes. The weight loss average of the three repeats is presented in Table 13.

[0299] Approximately 3-5 mg of each sample was weighed into a tared aluminum pan for analysis. The samples were heated using a temperature program with a ramp of 500°C / min to 210°C, followed by a temperature jump to 260°C. The heating procedure allowed the samples to heat from room temperature to 260°C in 1 min and then be held isothermal for an additional 4 min. Weight change was monitored from 0 to 5 min.

[0300] The results showed that most of the weight loss occurred within the first minute during the rapid heating process. During the first minute, the majority of the weight loss occurred in the control sample 17A (glycerin; 35.4%), while the least amount of weight loss occurred in sample 41A (glycerin-palmitic acid; 27.8%). This data supports the combination of glycerin with palmitic acid, triethylene glycol, or triacetin, particularly for more sustained release of aerosol from the substrate over time, which may be useful in providing less puff-to-puff variability. In contrast, the combinations of glycerin with 1,3-propanediol, or glycerin with propylene glycol were nearly indistinguishable from the glycerin control.

[0301] [Table 13]

[0302] Example 14: Preparation of cast sheets of HNB aerosol former substrate A series of six substrates containing various aerosol-forming materials were prepared using the ingredients and amounts shown in Table 14.

[0303] Aerosol former substrate 14A (reference substrate) Carboxymethylcellulose (CMC2500; 2.5 lbs) was slowly added to water (100 lbs) and hydrated under vacuum in a high shear mixing tank for 30 minutes. In a separate mixing tank, finely milled tobacco (12 lbs) was slowly added to glycerol (4 lbs) and water (5 lbs) and then gently mixed for 30 minutes to form a tobacco-water slurry. The hydrated CMC2500 was then mixed with zero freeness pre-refined wood pulp and transferred to a tobacco-water slurry tank, after which it was mixed under moderate mixing speed and vacuum for an additional 30 minutes to obtain the final slurry. The final slurry was then cast onto a 22-inch wide stainless steel conveyor belt using a casting knife set at a gap opening of 1-3 mm. The cast material (film) was subsequently dried into a flat sheet by conveying it through a 200 foot convection tunnel dryer containing multiple heating zones (80-100°C). The total dry batch weight was 20 lbs. The flat sheet was wound onto a bobbin and vacuum sealed in a polyethylene bag to prevent moisture absorption and blockage during shipping. The bobbin was then unwound and the sheet cut into strips (25-20 cuts per square inch).

[0304] Aerosol forming agent base 14B Aerosol former Base 14B was prepared similarly to Base 14A except that the glycerol was replaced with a 1:1 mixture of glycerol and palmitic acid by weight. The total batch weight was 20 lbs.

[0305] Aerosol forming agent base 14C Aerosol former Base 14C was prepared similarly to Base 14A, except that the glycerol was replaced with a 1:1 mixture of glycerol and triethylene glycol by weight. The total batch weight was 20 lbs.

[0306] Aerosol forming agent base 14D Aerosol former Base 14D was prepared similarly to Base 14A except that the glycerol was replaced with a 1:1 mixture of glycerol and triacetin by weight. The total batch weight was 20 lbs.

[0307] Aerosol forming agent base 14E (reference) Aerosol former Base 14E was prepared similarly to Base 14A, except glycerol was replaced with a mixture of glycerol and polyethylene glycol (1:1 by weight). Total batch weight was 20 lbs.

[0308] Aerosol forming agent base 14F Aerosol former Base 14F was prepared similarly to Base 14A, except that the glycerol was replaced with a 1:1.5:1.5 mixture of glycerol, palmitic acid, and 1,3-propanediol by weight. The total batch weight was 20 lbs.

[0309] [Table 14]

Claims

1. a first aerosol-forming material selected from the group consisting of glycerol, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, polyethylene glycol, triacetin, and combinations thereof; a second aerosol-forming material different from the first aerosol-forming material and selected from the group consisting of polysorbate, sorbitan ester, fatty acid, fatty acid ester, 1,3-propanediol, triethylene glycol, polyethylene glycol, triacetin, wax, cannabinoid, terpene, and sugar alcohol; an aerosol-generating member comprising a substrate impregnated with two or more aerosol-forming materials; wherein the first aerosol-forming material and the second aerosol-forming material each have different boiling points, different vapor pressures, or both; the substrate being impregnated with two or more aerosol-forming materials at a loading of 5 to 60% by weight based on the total weight of the impregnated substrate; the aerosol-generating member.

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

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

100.

4. The aerosol-generating member according to claim 1, wherein the weight ratio of the first aerosol-forming material to the second aerosol-forming material is from 3:1 to 1:

3.

5. The aerosol-generating member according to claim 1, 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 member according to claim 1, wherein the first aerosol-forming material is glycerol and the second aerosol-forming material is 1,3-propanediol, triethylene glycol, palmitic acid, or triacetin.

7. The aerosol-generating member according to claim 1, wherein the first aerosol-forming material is glycerol and the second aerosol-forming material is palmitic acid.

8. The first aerosol-forming material is 1,3-propanediol, triethylene glycol, propylene glycol, or triacetin; The second aerosol-forming material is palmitic acid, polyethylene glycol 400, sorbitan tristearate, or polysorbate 80. The aerosol generating member according to claim 1.

9. The aerosol generating member according to claim 1, wherein the base material is impregnated with a third aerosol-forming material selected from the group consisting of glycerol, palmitic acid, and 1,3-propanediol, triethylene glycol, propylene glycol, triacetin, polyethylene glycol 400, sorbitan tristearate, and polysorbate 80.

10. The base material is glycerol and palmitic acid, glycerol and 1,3-propanediol, glycerol 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, propylene glycol and palmitic acid, propylene glycol and polyethylene glycol, and propylene glycol and polysorbate 80 The aerosol generating member according to claim 1, which is impregnated with a mixture selected from the group consisting of The aerosol generating member according to claim 1.

11. The aerosol generating member according to claim 10, wherein the ratio of the aerosol-forming material in each of the listed mixtures is from 3:1 to 1:

3.

12. The aerosol generating member according to claim 1, wherein the base material is impregnated with a mixture containing glycerol, palmitic acid, and propylene glycol.

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

14. The aerosol generating member according to claim 1, wherein the base material further contains water in an amount of up to 10% by weight based on the total dry weight of the impregnated base material.

15. The aerosol generating member according to claim 1, wherein the base material contains 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 member according to claim 1, wherein the one or more binders are selected from alginates, cellulose derivatives, starches, gums, dextrans, carrageenans, calcium carbonate, or combinations thereof.

17. The base material is 40 to 70% by weight of tobacco-derived fibers, 10 to 15% by weight of a cellulose derivative, and 5 to 10% by weight of wood pulp The aerosol generating member according to claim 1, comprising.

18. The aerosol generating member according to claim 1, wherein the base material is further impregnated with a flavorant, an active ingredient, or a combination thereof.

19. The aerosol generating member according to claim 18, wherein the active ingredient comprises a tobacco component, a non-tobacco plant substance, a nicotine component, or a combination thereof.

20. The aerosol generating member according to claim 18, wherein the active ingredient comprises a nicotine component.

21. The aerosol generating member according to claim 1, wherein the base material takes the form of particles, shreds, film, paper process sheet, cast sheet, beads, granules, rods, or extrudates.

22. The aerosol generating member according to claim 21, wherein the base material is substantially formed in a cylindrical shape.

23. An aerosol generating member according to any one of claims 1 to 22, a heat source configured to heat the impregnated base material to form an aerosol, and an aerosol path extending from the aerosol generating member to the mouth end of the aerosol delivery device An aerosol delivery device comprising.

24. The aerosol delivery device according to claim 23, wherein the heat source comprises either an electric heating element or a combustible ignition source.

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

26. The aerosol delivery device according to claim 24, wherein the heat source is an electric heating element.

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

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

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