Aerosol-forming substrate containing microcrystalline cellulose

Abstract

The present disclosure provides a substrate comprising microcrystalline cellulose, a binder, an aerosol-forming material, and optionally an active ingredient, a flavoring agent, or both an active ingredient and a flavoring agent. The final form of the substrate can be configured to be used in an aerosol generating element for an aerosol delivery device. Further provided are aerosol generating elements and aerosol delivery devices comprising the substrate. Such devices provide a substance for inhalation in aerosol form by utilizing an electrical heating or combustible ignition source to heat the substrate.

Description

[Technical field]

[0001] The present disclosure relates to aerosol generating elements, aerosol delivery devices, and aerosol delivery systems that utilize electrical heat or combustible ignition sources to heat aerosol-forming materials to provide inhalable substances in aerosol form for humans, generally without significant combustion. [Background technology]

[0002] Many aerosol-producing products have been proposed over the years as improvements or alternatives to smoking products for use based on tobacco combustion. Some exemplary alternatives have included devices in which a solid or liquid fuel is burned to transfer heat to the tobacco or where a chemical reaction is used to provide such a heat source. Additional exemplary 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 point of improvement or replacement for aerosol-producing products has usually been to provide the sensation associated with cigarette, cigar, or pipe smoking without delivering a significant amount of incomplete combustion and pyrolysis products.To achieve this goal, many smoking products, flavor generating devices, and medicinal inhalers have been proposed that utilize electrical energy to vaporize or heat volatile materials, or have attempted to provide the sensation of cigarette, cigar, or pipe smoking without burning tobacco to a significant extent.See, for example, the various alternative smoking articles, aerosol delivery devices, and heat generating sources described in the background art described 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. [Prior art documents] [Patent documents]

[0004] [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 [Problem to be solved by the invention]

[0005] Articles that generate the taste and sensation of smoking by electrically heating tobacco, tobacco-derived materials, or other plant-derived materials have suffered from inconsistent performance characteristics. For example, some articles suffer from inconsistent release of flavors or other inhalation substances, insufficient loading of aerosol-forming materials onto the substrate, or poor sensory characteristics. Therefore, it would be desirable to provide a smoking article that can provide the sensation of cigarette, cigar, or pipe smoking, without burning the substrate material, and that does so with advantageous performance characteristics.

[0006] Aerosol delivery devices in which a solid fuel, e.g., carbon, is burned to transfer heat to the tobacco, as well as aerosol delivery devices that utilize electrical heating, have an aerosol-generating substrate as part of the aerosol-generating element. In both types of devices, it is advantageous to provide a substrate that has advantageous performance characteristics. [Means for solving the problem]

[0007] (Brief summary) The present disclosure relates to a substrate for use in an aerosol delivery device that utilizes electrical heating or a combustible ignition source to heat the substrate, thereby providing a substance for inhalation in aerosol form for humans. Thus, in one aspect, the present disclosure provides a substrate for use in an aerosol delivery device, the substrate comprising microcrystalline cellulose, one or more binders, and an aerosol-forming material.

[0008] In some embodiments, the microcrystalline cellulose is present in an amount of about 25% by weight or more, based on the total dry weight of the substrate. In some embodiments, the microcrystalline cellulose is present in an amount of 30% by weight or more, based on the total dry weight of the substrate. In some embodiments, the microcrystalline cellulose is present in an amount ranging from about 25 to about 60% by weight, from about 30 to about 55% by weight, or from about 35 to about 50% by weight, based on the total dry weight of the substrate.

[0009] In some embodiments, the substrate further comprises wood pulp in an amount of about 5 to about 15 weight percent, based on the total dry weight of the substrate.

[0010] In some embodiments, the binder is selected from the group consisting of a cellulose ether, an alginate, a starch, and combinations thereof. In some embodiments, the binder is a cellulose ether selected from the group consisting of methylcellulose, hydroxypropylcellulose, hydroxypropylmethylcellulose, hydroxyethylcellulose, carboxymethylcellulose, and combinations thereof. In some embodiments, the binder is carboxymethylcellulose. In some embodiments, the binder is an alginate.

[0011] In some embodiments, the aerosol forming material is present in an amount of about 10% by weight or more, based on the total dry weight of the substrate. In some embodiments, the aerosol forming material is present in an amount of about 20% by weight or more, based on the total dry weight of the substrate. In some embodiments, the aerosol forming material is present in an amount ranging from about 10 to about 70% by weight. In some embodiments, the aerosol forming material is present in an amount ranging from about 30 to about 60% by weight.

[0012] In some embodiments, the aerosol-forming material is selected from the group consisting of water, polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, non-fatty acid esters, waxes, cannabinoids, terpenes, sugar alcohols, and combinations thereof. In some embodiments, the aerosol-forming material is a polyhydric alcohol. 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.

[0013] In some embodiments, the substrate further comprises a flavoring agent, an active ingredient, or a combination thereof, hi some embodiments, the active ingredient comprises a nicotine ingredient.

[0014] In some embodiments, the substrate comprises about 30 to about 50% by weight microcrystalline cellulose, about 5 to about 10% by weight wood pulp, about 5 to about 10% by weight binder, and about 30 to about 60% by weight aerosol forming material.

[0015] In some embodiments, the binder is carboxymethylcellulose or sodium alginate.

[0016] In some embodiments, the aerosol forming material is glycerol.

[0017] In some embodiments, the substrate is in the form of a sheet.

[0018] In some embodiments, the substrate is substantially free of tobacco material.

[0019] In some embodiments, the substrate is substantially free of nicotine.

[0020] In another aspect, there is provided an aerosol generating element for use with an aerosol delivery device, the aerosol generating element comprising a substrate comprising microcrystalline cellulose, one or more binders and an aerosol-forming material.

[0021] In some embodiments, the aerosol generating element further comprises an aerosol-forming material, the aerosol-forming material comprising a tobacco material.

[0022] In some embodiments, the aerosol generating element further comprises a support, and the substrate is attached to the support.

[0023] In some embodiments, the support is flat.

[0024] In some embodiments, the substrate is blended with a tobacco material, hi some embodiments, the tobacco material is present as a plurality of strips.

[0025] In some embodiments, the aerosol generating element comprises a plurality of strips of substrate, hi some embodiments, the aerosol generating element comprises multiple layers of substrate.

[0026] In yet another aspect, an aerosol delivery device is provided that includes an aerosol generating element including a substrate comprising microcrystalline cellulose, one or more binders, and an aerosol-forming material; a heat source configured to heat the aerosol generating element to form an aerosol; and an aerosol pathway extending from the aerosol generating element and along a length configured to convey the aerosol to an orifice of the aerosol delivery device.

[0027] In some embodiments, the heat source includes either an electrically-driven 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 electrically-driven heating element. In some embodiments, the heat source is a conductive heat source or an inductive heat source.

[0028] In some embodiments, the aerosol delivery device further comprises an energy source electronically coupled to the heating element, hi some embodiments, the aerosol delivery device further comprises a controller configured to control the power delivered by the energy source to the heating element.

[0029] The present disclosure includes, without limitation, the following embodiments.

[0030] Embodiment 1: A substrate for use in an aerosol delivery device, the substrate comprising microcrystalline cellulose, one or more binders and an aerosol-forming material.

[0031] Embodiment 2: The substrate of embodiment 1, wherein the microcrystalline cellulose is present in an amount of about 25% by weight or more, based on the total dry weight of the substrate.

[0032] Embodiment 3: The substrate of embodiment 1 or 2, wherein the microcrystalline cellulose is present in an amount of 30% by weight or more, based on the total dry weight of the substrate.

[0033] Embodiment 4: The substrate of embodiment 1, wherein the microcrystalline cellulose is present in an amount ranging from about 25 to about 60% by weight, from about 30 to about 55% by weight, or from about 35 to about 50% by weight, based on the total dry weight of the substrate.

[0034] Embodiment 5: The substrate of any one of embodiments 1 to 4, further comprising wood pulp in an amount of about 5 to about 15% by weight, based on the total dry weight of the substrate.

[0035] Embodiment 6: The substrate of any one of embodiments 1 to 5, wherein the binder is selected from the group consisting of cellulose ethers, alginates, starches, and combinations thereof.

[0036] Embodiment 7: The substrate of any one of embodiments 1 to 6, wherein the binder is a cellulose ether selected from the group consisting of methyl cellulose, hydroxypropyl cellulose, hydroxypropyl methyl cellulose, hydroxyethyl cellulose, carboxymethyl cellulose, and combinations thereof.

[0037] Embodiment 8: The substrate of any one of embodiments 1 to 7, wherein the binder is carboxymethyl cellulose.

[0038] Embodiment 9: The substrate of any one of embodiments 1 to 6, wherein the binder is an alginate.

[0039] Embodiment 10: The substrate of any one of embodiments 1 to 9, wherein the aerosol-forming material is present in an amount of about 10% by weight or more, based on the total dry weight of the substrate.

[0040] Embodiment 11: The substrate of any one of embodiments 1 to 10, wherein the aerosol-forming material is present in an amount of about 20% by weight or more, based on the total dry weight of the substrate.

[0041] Embodiment 12: The substrate of any one of embodiments 1 to 11, wherein the aerosol-forming material is present in an amount ranging from about 10 to about 70% by weight.

[0042] Embodiment 13: The substrate of any one of embodiments 1 to 12, wherein the aerosol-forming material is present in an amount ranging from about 30 to about 60% by weight.

[0043] Embodiment 14: The substrate of any one of embodiments 1 to 13, wherein the aerosol-forming material is selected from the group consisting of water, polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, non-fatty acid esters, waxes, cannabinoids, terpenes, sugar alcohols, and combinations thereof.

[0044] Embodiment 15: The substrate of any one of embodiments 1 to 14, wherein the aerosol-forming material is a polyhydric alcohol.

[0045] Embodiment 16: The substrate according to any one of embodiments 1 to 15, wherein the polyhydric alcohol is selected from the group consisting of glycerol, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, and combinations thereof.

[0046] Embodiment 17: The substrate of any one of embodiments 1-16, further comprising a flavoring agent, an active ingredient, or a combination thereof.

[0047] Embodiment 18: The substrate of any one of embodiments 1 to 17, wherein the active ingredient comprises a nicotine ingredient.

[0048] Embodiment 19: The substrate of any one of embodiments 1 to 18, comprising about 30 to about 50% by weight of microcrystalline cellulose, about 5 to about 10% by weight of wood pulp, about 5 to about 10% by weight of a binder, and about 30 to about 60% by weight of an aerosol-forming material.

[0049] Embodiment 20: The substrate of embodiment 19, wherein the binder is carboxymethylcellulose or sodium alginate.

[0050] Embodiment 21: The substrate of embodiment 19 or 20, wherein the aerosol-forming material is glycerol.

[0051] Embodiment 22: The substrate of any one of embodiments 1 to 21, in the form of a sheet.

[0052] Embodiment 23: The substrate of any one of embodiments 1 to 22, wherein the substrate is substantially free of tobacco material.

[0053] Embodiment 24: The substrate of any one of embodiments 1 to 23, which is substantially free of nicotine.

[0054] Embodiment 25: An aerosol generating element for use with an aerosol delivery device, comprising a substrate according to any one of embodiments 1 to 25.

[0055] Embodiment 26: An aerosol generating element as described in embodiment 25, further comprising an aerosol generating material, the aerosol generating material comprising a tobacco material.

[0056] Embodiment 27: An aerosol generating element according to embodiment 25 or 26, further comprising a support, wherein the substrate is attached to the support.

[0057] Embodiment 28: An aerosol generating element according to any one of embodiments 25 to 27, wherein the support is flat.

[0058] Embodiment 29: An aerosol generating element according to any one of embodiments 25 to 28, wherein the substrate is blended with a tobacco material.

[0059] Embodiment 30: An aerosol generating element according to any one of embodiments 26 to 29, wherein the tobacco material is present as a plurality of strips.

[0060] Embodiment 31: An aerosol generating element according to any one of embodiments 25 to 30, comprising a substrate of a plurality of strips.

[0061] Embodiment 32: An aerosol generating element according to any one of embodiments 25 to 30, comprising a substrate having multiple layers.

[0062] Embodiment 33: An aerosol delivery device comprising: an aerosol generation element according to any one of embodiments 25 to 32; a heat source configured to heat the aerosol generation element to form an aerosol; and an aerosol pathway extending from the aerosol generation element and along a length configured to convey the aerosol to an oral portion of the aerosol delivery device.

[0063] Embodiment 34: An aerosol delivery device as described in embodiment 33, wherein the heat source comprises either an electrically-operated heating element or a combustible ignition source.

[0064] Embodiment 35: An aerosol delivery device according to embodiment 33 or 34, wherein the heat source is a combustible ignition source comprising a carbon-based material.

[0065] Embodiment 36: An aerosol delivery device described in embodiment 33 or 34, wherein the heat source is an electrically-operated heating element.

[0066] Embodiment 37: The aerosol delivery device of embodiment 36, further comprising an energy source electronically coupled to the heating element.

[0067] Embodiment 38: The aerosol delivery device described in embodiment 37, further comprising a controller configured to control the power delivered by the energy source to the heating element.

[0068] Embodiment 39: An aerosol delivery device described in any one of embodiments 33 to 38, wherein the heat source is a conductive heat source or an inductive heat source.

[0069] These and other features, aspects and advantages of the present disclosure will become apparent from the following detailed description read in conjunction with the accompanying figures, which are briefly described below. The present invention includes any combination of two, three, four or more of the above-described embodiments, as well as any combination of two, three, four or more of the features or elements described in this disclosure, regardless of whether such features or elements are explicitly combined in the description of a particular embodiment herein. The present disclosure is intended to be read as a whole, whereby it should be considered that any separable features or elements of the disclosed invention are intended to be combinable in any of its various aspects and embodiments, unless such context clearly dictates otherwise.

[0070] Having thus described aspects of the present disclosure in the foregoing general terms, reference is now made to the accompanying figures, which are not necessarily drawn to scale and are illustrative only and should not be construed as limiting the disclosure. [Brief description of the drawings]

[0071] [Figure 1] 1 illustrates a schematic perspective view of an aerosol generating element including a support and a substrate. [Diagram 2] 1 illustrates a perspective view of an aerosol delivery device including a controller and an aerosol generating element, the aerosol generating element and the controller being coupled to each other, according to an exemplary embodiment of the present disclosure; [Diagram 3]2 illustrates a perspective view of the aerosol delivery device of FIG. 1, in which the aerosol generation element and the control device are separated from each other, according to an exemplary embodiment of the present disclosure. [Figure 4] 1 illustrates a schematic perspective view of an aerosol generating element according to an exemplary embodiment of the present disclosure. [Diagram 5] 1 illustrates a schematic cross-sectional view of a substrate portion of an aerosol generating element according to an exemplary embodiment of the present disclosure. [Figure 6] 1 illustrates a perspective view of an aerosol generating element according to an exemplary embodiment of the present disclosure. [Figure 7] FIG. 7 illustrates a perspective view of the aerosol generating element of FIG. 6 with the outer packaging removed, according to one embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0072] The present disclosure will now be described more fully hereinafter with reference to exemplary embodiments thereof. These exemplary embodiments are provided 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 present disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will meet applicable legitimate requirements.

[0073] As used in this specification and the claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0074] The term "about" used throughout this specification is used to describe and explain small variations. For example, the term "about" can refer to less than or equal to ±10%, for example, 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 with the term "about", whether or not expressly stated. Values ​​modified with the term "about" naturally include the specific value. For example, "about 5.0" must include 5.0.

[0075] References to percentages are intended to mean weight percentages unless otherwise indicated. All weight percentages described herein are calculated on a dry weight basis unless expressly stated otherwise. References to "dry weight percentages" or "dry weight basis" refer to weights based on dry components (i.e., all components except water). Weights presented on a dry weight basis refer to the totality of the slurry, material, etc., other than water or other solvent, and may include components that are themselves liquid at room temperature and pressure, such as glycerol or other aerosol-forming materials. Conversely, weight percentages presented on a wet weight basis refer to all components, including water or other solvent.

[0076] Base material As described herein below, exemplary embodiments of the present disclosure relate to substrates for use in aerosol delivery devices. Substrates can include a variety of materials, either alone or in combination. Substrates of the present disclosure generally include fillers, binders, aerosol-forming materials, and optionally active ingredients, flavorings, or both. Each of the substrate components is further described herein below.

[0077] filling material The substrates disclosed herein include a filler. The filler can include, for example, non-tobacco plant materials, cellulosic materials, wood fibers or pulps, starches, sugars, sugar alcohols, inorganic substances, inert materials, and the like materials, and combinations thereof. The amount of filler can vary. In some embodiments, the substrate includes up to about 70% dry weight of the filler, based on the total dry weight of the substrate. For example, in some embodiments, the substrate includes about 30% to about 70% by weight of the filler, based on the total dry weight of the substrate. More than one filler can be used. In such embodiments, it is understood that references to weight percent of the filler are intended to reflect the total amount of the combination of fillers present in the substrate.

[0078] Microcrystalline Cellulose In some embodiments, microcrystalline cellulose ("mcc") is used as a filler in the substrate. In addition to functioning as a filler, the microcrystalline cellulose material used herein can function in certain embodiments as a carrier, for example, as a carrier for flavoring agents. Microcrystalline cellulose has many uses, such as a conditioner, anti-caking agent, fat substitute, emulsifier, extender and bulking agent, as well as an excipient for direct compression, a binder, a disintegrant, an absorbent, a filler, a diluent, a lubricant and an anti-adhesive agent. In contrast to other cellulosic materials that are obtained directly from pulp, microcrystalline cellulose is a refined pulp product. Pulp is a lignocellulosic fibrous material prepared by chemically or mechanically separating cellulose fibers from wood, fiber crops, waste paper or rags, while microcrystalline cellulose is distinguished as refined, partially depolymerized cellulose.

[0079] Cellulose is a naturally occurring polymer composed of glucose units linked by 1-4 β-glycosidic bonds. Linear cellulose is bundled together as microfibrils in plant cell walls. Each microfibril defines a crystalline structure that is insoluble in water and resistant to reagents. However, the microfibrils contain amorphous regions with weaker internal bonds. The crystalline structures are isolated to produce microcrystalline cellulose. Microcrystalline cellulose can be produced only from alpha cellulose (also known as "chemical cellulose"), which is a highly purified, insoluble, relatively high molecular weight cellulose from which sugars, pectins, and other soluble materials have been removed. In relation to other types of cellulose, β cellulose is defined as a more degraded form of cellulose with fewer crystalline regions. Furthermore, γ cellulose is defined as a short-chain hemicellulose. Thus, β cellulose and γ cellulose are usually removed from the inputs utilized to produce microcrystalline cellulose.

[0080] In the production of microcrystalline cellulose, alpha cellulose can be first chopped and then immersed in a hot bath of mineral acid to dissolve the amorphous regions of the microfibrils while leaving the microcrystalline structure intact. The microcrystalline structure can then be subjected to hydrolysis to break the long polymer chains until the degree of polymerization is reduced and stabilized to a desired degree. Chemicals and impurities can then be removed via washing with water followed by drying. The resulting microcrystalline cellulose can be embodied in raw form as a fine white crystallized powder. Methods for forming microcrystalline cellulose from plant materials are described, for example, in U.S. Patent No. 9,339,058 to Byrd, Jr. et al. and U.S. Patent No. 10,774,472 to Sebastian et al., both of which are incorporated herein by reference in their entireties. MCC materials are commercially available from manufacturers such as, for example, DuPont de Nemours, Inc., Asahi Kasei Corporation, Sigachi Industries Limited, Accent Microcell Pvt. Ltd., and DFE Pharma GmbH & Co. KG. The microcrystalline cellulose can be selected from the group consisting of AVICEL® grades PH-100, PH-102, PH-103, PH-105, PH-112, PH-113, PH-200, PH-300, PH-302, VIVACEL® grades 101, 102, 12, 20, and EMOCEL® grades 50M and 90M, and the like, and mixtures thereof.

[0081] Microcrystalline cellulose is usually used in particulate form, and the size of the particles can vary.In certain embodiments, the microcrystalline cellulose material is in very fine particulate form, for example, particles with a D90 particle size of about 250 microns or less, for example, about 170 microns or less, or about 150 microns or less.As used herein, the term "D90 particle size" means that 90% of all particles are smaller than a given size.Particle size can be measured, for example, by laser diffraction or using a particle size analyzer.

[0082] In certain embodiments, the microcrystalline cellulose material has a relatively low bulk density compared to other types of cellulose materials, which is advantageous when a material with a higher loading value is desired. An exemplary range of bulk density for the microcrystalline cellulose materials used in the present disclosure is about 0.50 g / mL or less, for example, about 0.26 to about 0.35 g / mL or about 0.26 to about 0.5 g / mL, as determined by measuring the volume of a powder of known mass.

[0083] In some embodiments, compared to other cellulosic materials, microcrystalline cellulose can advantageously provide one or more of improved texture, anti-caking and anti-sticking properties to substrates that include microcrystalline cellulose.

[0084] The amount of microcrystalline cellulose present in the substrate may vary. In some embodiments, the substrate comprises about 25% or more microcrystalline cellulose on a dry weight basis, e.g., about 25 to about 60% microcrystalline cellulose, about 30 to about 55% or about 35 to about 50% microcrystalline cellulose on a dry weight basis. In some embodiments, the substrate comprises from about 25%, about 30%, about 35%, about 40% or about 45% to about 50%, about 55% or about 60% microcrystalline cellulose on a dry weight basis.

[0085] Other cellulosic materials In some embodiments, the filler comprises additional cellulosic materials, such as cellulosic materials derived from flax, cotton linters, kenaf, hibiscus, hemp, tobacco, sisal, rice straw, or esparto. Other suitable cellulosic materials include, but are not limited to, cereal grains (e.g., corn, oat, barley, rye, buckwheat, etc.), sugar beet (e.g., FIBREX® brand filler available from International fiber Corporation), bran fibers, and mixtures thereof.

[0086] In some embodiments, the cellulosic material is a cellulosic pulp or regenerated cellulose that contains at least about 90% by weight cellulose, e.g., about 90%, about 95%, about 99%, or even up to 100% by weight cellulose. By "regenerated cellulose" is meant natural cellulose that has been regenerated by conversion to a soluble or dissolvable cellulosic derivative and subsequently formed into fibers, usually via polymer spinning or via film polymer casting, precipitation or extrusion.

[0087] In some embodiments, the cellulosic material comprises a nanocellulose material. As used herein, "nanocellulose material" refers to a cellulosic material having at least one average particle size dimension in the range of about 1 nm to about 100 nm. As non-limiting examples, suitable nanocellulose materials may be fibrous materials prepared from any suitable cellulose-containing material, such as grasses (e.g., bamboo), cotton, tobacco, algae, and other plant-based materials, where the fibers are further refined to produce nanofibrillated cellulose fibers.

[0088] Wood Fiber In some embodiments, the filler comprises wood or wood-derived fibers (e.g., wood pulp). For example, in some embodiments, the substrate comprises about 0 to about 15% wood pulp, e.g., about 1% to about 15% or about 5 to about 15% wood pulp, on a dry weight basis. In some embodiments, the substrate comprises about 5 to about 11% or about 5 to about 9% wood pulp, e.g., about 5, about 6, about 7, about 8, about 9, about 10, or about 11% wood pulp, on a dry weight basis. The presence of wood pulp can enhance the structural integrity of the substrate sheet material.

[0089] In other embodiments, the substrate is substantially or completely free of wood fiber or wood pulp. By "substantially free" of wood fiber or pulp, it is meant that no wood fiber or pulp has been intentionally added, e.g., beyond trace amounts that may be naturally present in plants or other plant materials. For example, certain embodiments may be characterized as having less than 0.1% by dry weight, or less than 0.01% by dry weight, or less than 0.001% by dry weight, or 0% by dry weight of wood fiber or pulp, based on the total dry weight of the substrate.

[0090] In some embodiments, the filler comprises a combination of microcrystalline cellulose and wood pulp.In some embodiments, the filler is a combination of microcrystalline cellulose and wood pulp.

[0091] Non-tobacco plants In some embodiments, the filler material comprises non-tobacco plant material. As used herein, the term "plant material" or "plant" refers to any plant material or fungal-derived material, including plant material in its natural form and plant material derived from natural plant material, such as extracts or isolates from plant material, or processed plant material (e.g., plant material subjected to heat treatment, fermentation, or other treatment processes that can modify the chemical properties of the material). For purposes of this disclosure, "plant material" includes, but is not limited to, "herbal materials," which refer to seed-producing plants that do not produce persistent xylem tissue and are often valued for their medicinal or sensory properties (e.g., tea or tisane). Calling a plant material "non-tobacco" is intended to exclude tobacco material (i.e., does not include any Nicotiana species). Plant material as used in this disclosure can include any of the compounds and sources described herein, including mixtures thereof, without limitation. Certain plant materials of this type are sometimes referred to as dietary supplements, nutraceuticals, "phytocompounds," or "functional foods."

[0092] Non-limiting examples of non-tobacco plant materials include, without limitation, acai berry (Euterpe oleracea martius), acerola (Malpighia glabra), alfalfa, allspice, angelica root, anise (e.g., star anise), annatto seed, apple (Malus domestica), apricot oil, bacopa monniera, basil (Ocimum basilicum), bee balm, beetroot, bergamot, blackberry (Morus nigra), black cohosh, black pepper, black tea, blueberry, boldo (Peumus boldus), borage, ambrosia, cacao, calamus root, camu camu (Myrcaria dubia), hemp / marijuana, caraway seed, catnip, catuaba, cayenne, cayenne pepper, chaga, chamomile, cherry, chervil, chocolate, cinnamon (Cinnamomum cassia), citron grass (Cymbopogon citratus), clary sage, cloves, coconut (Cocos nucifera), coffee, comfrey, coriander seed, cranberry, dandelion, echinacea, elderberry, elderberry, endro (Anethum gravellens) graveolens), evening primrose, eucalyptus, fennel, feverfew, garlic, ginger (Zingiber officinale), ginkgo biloba, ginseng, goji berries, goldenseal, grape seeds, grapefruit, pink grapefruit (Citrus paradisi), graviola (Annona muricata), green tea, gotu kola, hawthorn, hibiscus flower (Hibiscus sabdariffa),sabdariffa), honeybush, gynostemma, kava, jambu (Spilanthes oleraceae), jasmine (Jasminum officinale), juniper berry (Juniperus communis), lavender, lemon (Citrus limon), licorice, lilac, Yamabushitake mushroom, maca (Lepidium meyenii), marjoram, milk thistle, mint, oolong tea, orange (Citrus sinensis), oregano, papaya, pennyroyal mint, peppermint (Mentha piperita) piperita), potato skins, quince, red clover, rooibos (red or green), rose hips (Rosa canina), rosemary, sage, St. John's wort, salvia (Salvia officinalis), savory, saw palmetto, silybum marianum, slippery elm bark, high tannin sorghum bran, high tannin sorghum grain, spearmint (Mentha spicata), spirulina, sumac bran, thyme, turmeric, bearberry, valerian, vanilla, wild yam root, wintergreen, withania somnifera, yacon root, yellow dock, yerba mate, and yerba santa.

[0093] In some embodiments, the substrate comprises non-tobacco materials of plant origin, including, but not limited to, eucalyptus, rooibos, star anise, fennel, hemp, flax, sisal, rice straw, esparto, and combinations thereof.

[0094] The amount of non-tobacco plant material present may vary and is generally less than about 50% by weight of the substrate, based on the total dry weight of the substrate. For example, the non-tobacco plant material may be present in an amount of about 0%, about 0.1%, about 0.5%, about 1%, about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, or about 50% by weight of the substrate, based on the total dry weight of the substrate.

[0095] Starch and sugar In some embodiments, the filler comprises starch, including native and modified starches. Certain starch materials may also be included in the substrate as binders or other functional additives. "Starch" as used herein can refer to pure starch from any source, modified starch, or starch derivatives. Starch is usually present in granular form in almost all green plants and in various types of plant tissues and organs (e.g., seeds, leaves, rhizomes, roots, tubers, shoots, fruits, grains, and stems). Starch can vary in composition and granular shape and size. Starches from different sources often have different chemical and physical characteristics. A particular starch can be selected for inclusion in the beads based on the ability of the starch material to impart certain sensory properties to the beads. Starch from a variety of sources can be used. For example, major sources of starch include cereal grains (e.g., rice, wheat, and corn) and root plants (e.g., potato and cassava). Other examples of starch sources include acorn, arrowroot, arracacha, banana, barley, legumes (e.g., fava, lentil, mung bean, bean, chickpea), breadfruit, buckwheat, canna, chestnut, taro, dogtooth violet, kudzu, malanga, millet, oat, oka, yam, sago, sorghum, sweet potato, quinoa, rye, tapioca, taro, tobacco, water chestnut, and yam. Suitable starches include, but are not limited to, corn starch, rice starch, tapioca starch, and modified edible starches. Certain starches are modified starches. Modified starches have one or more structural modifications, often designed to change their thermogenic properties. Some starches are produced by genetic modification and are considered to be "modified" starches. Other starches are obtained and then modified.For example, modified starches can be starches that have been subjected to chemical reactions, such as esterification, etherification, oxidation, depolymerization (thinning) by acid catalysis or oxidation in the presence of a base, bleaching, transglycosylation and depolymerization (e.g., dextrinization in the presence of a catalyst), crosslinking, enzymatic treatment, acetylation, hydroxypropylation and / or partial hydrolysis. Other starches are modified by heat treatment, such as pregelatinization, dextrinization and / or cold water swelling processes. Certain modified starches include monostarch phosphate, distarch glycerol, distarch phosphate esterified with sodium trimetaphosphate, phosphate distarch phosphate, acetylated distarch phosphate, starch acetate esterified with acetic anhydride, starch acetate esterified with vinyl acetate, acetylated distarch adipate, acetylated distarch glycerol, hydroxypropyl starch, hydroxypropyl distarch glycerol and sodium starch octenyl succinate.

[0096] In some embodiments, the filler comprises corn starch, rice starch or rice flour, food modified starch, or combinations thereof. In other embodiments, the substrate is substantially or completely free of rice starch and rice flour. By "substantially free" of rice starch and rice flour, it is meant that no rice starch or flour has been intentionally added beyond trace amounts that may be naturally present, for example, in another starch material. For example, certain embodiments may be characterized as having less than 0.1% by dry weight, or less than 0.01% by dry weight, or less than 0.001% by dry weight, or 0% by dry weight of rice starch and rice flour, based on the total dry weight of the substrate.

[0097] In some embodiments, the filler comprises a sugar. Suitable sugars include, but are not limited to, glucose, dextrose, fructose, maltose and lactose.

[0098] In some embodiments, the filler comprises a sugar alcohol. Suitable sugar alcohols include, but are not limited to, sorbitol, mannitol, isomalt, maltitol, erythritol and xylitol.

[0099] Inorganic and inert materials In some embodiments, the filler material includes inorganic or inert materials, such as, but not limited to, chitosan, carbon (graphite, diamond, fullerene, graphene), quartz, granite, diatomaceous earth, calcium carbonate, calcium phosphate, clay, crustacean and other marine shells, or combinations thereof. In some embodiments, the substrate material can include various types of inorganic fibers (e.g., fiberglass, metal wire / screen, etc.) and / or (organic) synthetic polymers. In some embodiments, these "fibrous" materials can be unstructured (e.g., randomly distributed, such as cellulose fibers in a tobacco cast sheet) or structured (e.g., wire mesh) materials.

[0100] Binder The substrates disclosed herein include a binder. The binder (or combination of binders) can be utilized in an amount sufficient to provide the substrate with the desired physical characteristics and physical integrity. The amount of binder utilized can vary. In some embodiments, the binder is present in an amount of about 1%, 5%, 10%, 15%, 20%, 25%, 30%, or 35% by weight, up to about 40%, 45%, 50%, 55%, or 60% by weight, based on the dry weight of the substrate. Certain embodiments are characterized by a binder content of at least about 1% by weight, e.g., about 1 to about 30% by weight, or about 1 to about 20% by weight, or about 5 to about 15% by weight, based on the total wet weight of the substrate. In some embodiments, the binder is present in an amount of about 5 to about 9% by weight, or about 7 to about 11% by weight, or about 6 to about 12% by weight, based on the total dry weight of the substrate.

[0101] Typical binders can be organic or inorganic or combinations thereof. Representative binders include povidone, alginates, seaweed hydrocolloids, pectins, starches, gums, carrageenan, pullulan, zein, cellulose derivatives, and the like, and combinations thereof. In some implementations, combinations or blends of two or more binder materials can be utilized.

[0102] In some embodiments, the binder comprises an alginate, pectin, agar, agarose, gelatin, carrageenan, gum, cellulose derivative, pullulan, starch or its derivatives, silica or silicone compounds, clay, polymer, or combinations thereof.

[0103] In some embodiments, the binder comprises an alginate, such as ammonium alginate, propylene glycol alginate, potassium alginate or sodium alginate. Alginates, particularly high viscosity alginates, can be utilized as crosslinkers in conjunction with controlled levels of free calcium ions. In some embodiments, the substrate comprises about 1 to about 15% by weight alginate, for example about 5 to about 10% by weight alginate, on a dry weight basis, based on the total dry weight of the substrate.

[0104] In some embodiments, the binder comprises pectin. In some embodiments, the binder comprises alginate and / or pectin, which may be combined with a stiffening agent (e.g., a calcium source) during formation of the substrate. In some embodiments, the substrate may comprise calcium cross-linked alginate, calcium cross-linked or acid cross-linked pectin, or both.

[0105] In some embodiments, the binder comprises a gum, for example a natural gum. As used herein, natural gum refers to a polysaccharide material of natural origin that has binding properties and is also useful as a thickening or gelling agent. Representative natural gums derived from plants, which are usually water-soluble to some extent, include xanthan gum, guar gum, gum arabic, ghatti gum, tragacanth gum, gum karya, locust bean gum, gellan gum, and combinations thereof. In some embodiments, the binder comprises xanthan gum, guar gum, gum arabic, locust bean gum, tragacanth gum, or combinations thereof.

[0106] In some embodiments, the binder comprises silica, fumed silica, sodium silicate, polydimethylsiloxane, kaolin, polyvinyl alcohol, or combinations thereof.

[0107] In some embodiments, the binder comprises a cellulose ether (including a carboxyalkyl ether), which refers to a cellulose polymer in which the hydrogen of one or more hydroxyl groups in the cellulose structure is replaced with an alkyl, hydroxyalkyl, or aryl group. Non-limiting examples of such cellulose derivatives include methylcellulose, hydroxypropylcellulose ("HPC"), hydroxypropylmethylcellulose ("HPMC"), hydroxyethylcellulose, and carboxymethylcellulose ("CMC"). Suitable cellulose ethers include: hydroxypropylcellulose, such as Klucel H, available from Aqualon Co.; hydroxypropylmethylcellulose, such as Methocel K4MS, available from DuPont; hydroxyethylcellulose, such as Natrosol 250 MRCS, available from Aqualon Co.; methylcellulose, such as Methocel A4M, K4M, and E15, available from DuPont; and sodium carboxymethylcellulose, such as CMC 7HF, CMC 7LF, and CMC 7H4F, available from Aqualon Co. In some embodiments, the binder is one or more cellulose ethers (e.g., a single cellulose ether, or, for example, several cellulose ethers, for example, a combination of two or three). In some embodiments, the binder is a cellulose ether selected from the group consisting of methylcellulose, hydroxypropylcellulose, hydroxypropylmethylcellulose, hydroxyethylcellulose, carboxymethylcellulose, and combinations thereof. In some embodiments, the binder is carboxymethylcellulose. In some embodiments, the binder is hydroxypropylmethylcellulose.

[0108] In some embodiments, the substrate comprises carboxymethylcellulose in an amount of about 5 to about 11 weight percent or about 7 to about 9 weight percent, based on the dry weight of the substrate.

[0109] Aerosol-forming materials The substrate disclosed herein comprises an aerosol-forming material. Suitable aerosol-forming materials include, but are not limited to, water, polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, terpenes, sugar alcohols, tobacco extracts, and combinations thereof. In some embodiments, the aerosol-forming material can comprise water, polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, triacetin, waxes, terpenes, cannabinoids, sugar alcohols, tobacco extracts, or any combinations thereof. Each of the polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, terpenes, and sugar alcohols is further described herein below.

[0110] The amount of aerosol-forming material incorporated (e.g., carried or impregnated) in the substrate may vary, and is generally such that the aerosol-generating element containing the substrate provides acceptable sensory properties and desirable performance characteristics. For example, it is highly preferred that a sufficient amount of aerosol-forming material is utilized to provide the generation of visible mainstream aerosol that is similar in appearance to tobacco smoke in many respects. The amount of forming material in the aerosol-generating element (e.g., impregnated substrate) may depend on factors such as the number of puffs desired per aerosol-generating element.

[0111] In some embodiments, the substrate, when loaded, comprises at least about 0.1 wt.%, at least about 0.5 wt.%, at least about 1 wt.%, at least about 5 wt.%, at least about 10 wt.%, at least about 15 wt.%, at least about 20 wt.%, at least about 25 wt.%, at least about 30 wt.%, at least about 35 wt.%, at least about 40 wt.%, at least about 45 wt.%, at least about 50 wt.%, at least about 55 wt.%, at least about 60 wt.%, at least about 65 wt.%, at least about 70 wt.%, at least about 75 wt.%, or at least about 80 wt.% of the aerosol-forming material, based on the total dry weight of the impregnated substrate. Exemplary ranges of the total aerosol-forming material include from about 5 to about 80%, from about 10 to about 70%, or from about 20 to about 60%, e.g., from about 15% to about 55%, from about 15% to about 30%, or from about 15% to about 25%, based on the total dry weight of the impregnated substrate. In some embodiments, the substrate comprises the aerosol-forming material in an amount of about 10 to about 70 weight percent, about 40 to about 60 weight percent, about 30 to about 60 weight percent, or about 25 to about 45 weight percent, based on the dry weight of the substrate.

[0112] Polyhydric alcohol In some embodiments, the aerosol-forming material comprises one or more polyhydric alcohols, examples of which include glycerol (i.e., glycerin), propylene glycol, other glycols such as 1,3-propanediol, diethylene glycol and triethylene glycol, and polyethylene glycols (e.g., PEG molecules in the weight average molecular weight range of about 200 to about 2,000 Da).

[0113] 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. In some embodiments, the aerosol forming material is glycerol.

[0114] In some embodiments, the polyhydric alcohol is a mixture of glycerol and propylene glycol. Glycerol and propylene glycol may be present in various ratios, with more of either component present depending on the intended use. In some embodiments, glycerol and propylene glycol are present in a weight ratio of about 3:1 to about 1:3. In some embodiments, 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, glycerol and propylene glycol are present in a weight ratio of about 1:1.

[0115] Polysorbates and Sorbitan Esters 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 or combination of polysorbates used depends on the intended desired effect, as different polysorbates provide different properties depending on the size of the molecule. For example, polysorbate molecules increase in size from polysorbate 20 to polysorbate 80. Using smaller sized polysorbate molecules produces lower vapor volume but allows deeper lung penetration. This can be desirable when the user is in a public place where they do not want to produce a large plume of "smoke" (i.e. vapor). Conversely, when a high density vapor is desired, larger polysorbate molecules can be utilized as they are able to deliver the aromatic constituents of tobacco. An added benefit of using the polysorbate family of compounds is that polysorbates reduce the heat of vaporization of mixtures in which they are present.

[0116] 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).

[0117] Fatty acids, esters and waxes In some embodiments, the aerosol-forming material comprises one or more fatty acids. The fatty acids can include short-chain, long-chain, saturated, unsaturated, straight-chain, or branched-chain carboxylic acids. The fatty acids can be C4 to C6. 28 Generally includes aliphatic carboxylic acids. 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.

[0118] 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 tributyrate, and glycerol trihexanoate.

[0119] In some embodiments, the aerosol forming material comprises one or more non-fatty acid esters, examples of which include, but are not limited to, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenyl acetate, and propylene carbonate.

[0120] In some embodiments, the aerosol-forming material comprises one or more waxes, such as carnauba, beeswax, and candelilla, which are known to stabilize aerosol particles, improve palatability, or reduce throat irritation.

[0121] Terpenes In some embodiments, the aerosol-forming material comprises one or more terpenes. As used herein, the term "terpene" refers to a hydrocarbon compound biosynthetically produced by plants from isopentenyl pyrophosphate. Non-limiting examples of terpenes include limonene, pinene, farnesene, myrcene, geraniol, fennel, and cembrene.

[0122] Sugar alcohols In some embodiments, the aerosol-forming material comprises one or more sugar alcohols. Examples of sugar alcohols include sorbitol, erythritol, mannitol, maltitol, isomalt and xylitol. Sugar alcohols can also function as flavor enhancers for certain flavor compounds, such as menthol and other volatiles, and generally improve the mouthfeel, texture, throat effect and other sensory properties of the generated aerosol.

[0123] In some embodiments, the aerosol forming material comprises glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, propylene carbonate, or any combination thereof, In some embodiments, the aerosol forming material comprises, consists essentially of, or consists of glycerol.

[0124] active ingredient In some embodiments, the substrate comprises one or more active ingredients.The active ingredient may be a component of the aerosol-forming material, or may be impregnated, or may be otherwise incorporated separately into the substrate.For example, impregnation may be carried out during the preparation of the substrate material, after the substrate is formed, or both.

[0125] As used herein, "active ingredient" refers to one or more substances that belong to any of the following categories: APIs (active pharmaceutical agents), food additives, natural medicines, and naturally occurring substances that can have an effect on humans. Exemplary 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 action 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., produce a stimulating effect on the central nervous system, have an energizing effect, an antipyretic or analgesic effect, or have an otherwise beneficial effect on the body). In some embodiments, the active ingredient can be of the type commonly referred to as a dietary supplement, nutraceutical, "botanical compound," or "functional food." These types of additives are sometimes defined in the art to include substances that provide one or more beneficial biological effects (e.g., health promotion, disease prevention, or other pharmacological effects), but are normally available from naturally occurring sources (e.g., plant materials) that are not classified or regulated as drugs.

[0126] 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, having therapeutic, prophylactic or diagnostic activity. 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 / or 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 characteristics of the particular product.

[0127] 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, about 1% w / w to about 10% by weight, about 1% w / w 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 from about 0.001%, about 0.01%, about 0.1%, or about 1% by weight, up to about 20% by weight, 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 0.06%, about 0.07%, or about 10% by weight, based on the total weight of the composition. The active ingredient may be present in a concentration of 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% by weight, up 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 particular active ingredients are provided herein below.

[0128] plant In some embodiments, the active ingredient comprises one or more non-tobacco plants. As used herein, the term "plant ingredient" or "plant" refers to any plant material, including plant material in its natural form (e.g., leaves, bark, fiber, stems, roots, seeds, flowers, fruits, pollen, husks, shells, etc.) and plant material derived from natural plant material, such as an extract or isolate from a plant material, or processed plant material (e.g., plant material that has been subjected to heat treatment, fermentation, or other treatment processes that can modify the chemical properties of the material).

[0129] For purposes of this disclosure, "plant material" includes, but is not limited to, "herbal material," which refers to seed-producing plants that do not produce persistent xylem tissue and are often valued for their medicinal or sensory properties (e.g., tea or tisane). Calling a plant material "non-tobacco" is intended to exclude tobacco material (i.e., not including any Nicotiana species). The plant material used in the present invention can include, without limitation, any of the compounds and sources described herein, including mixtures thereof. Certain plant materials of this type are sometimes referred to as dietary supplements, nutraceuticals, "phytocompounds" or "functional foods."

[0130] Non-limiting examples of botanical materials, many of which have antioxidant properties, include, without limitation, acai berry, alfalfa, allspice, aniseed, annatto seed, apricot oil, ashwagandha, bacopa monniera, baobab, basil, bay, bee balm, beetroot, bergamot, black pepper, black tea, blueberry, borage seed oil, burdock, cacao, calamus root, cardamom, black currant, catnip, catuaba, cayenne pepper, Centella asiatica, chaga, bupleurum, chamomile, cherry blossom, chervil, chives, chlorophyll, dark chocolate, cilantro, cinnamon, citrus, clove, cocoa, coffee, comfrey, black cohosh, cordyceps, coriander, cranberry, cumin, curcumin, damiana, dandelion, Dorstenia arifolia, arifolia, Dorstenia odorata, Echinacea, Elderberry, Eucalyptus, Fennel, Feverfew, Flax, Galphimia glauca, Garlic, Geranium, Ginger, Ginkgo biloba, Ginseng (e.g. Panax ginseng), Goji berry, Goldenseal, Grape seed, Green tea, Grapefruit, Griffonia simplicifolia, Guarana, Gotu kola, Hawthorn, Hazel, Cannabis, Hibiscus flower, Honeybush, Hops, Jasmine, Gynostemma pentaphyllum, Juniper, Kaempferia parviflora parviflora (black ginger), kava, laurel, lavender, lemon, lemon balm, lemongrass, licorice, yamabushitake, lutein, maca, mace, marjoram, matcha, mulberry, Nardostachys chinensis, marjoram, milk thistle, mint, myrtle, nutmeg, olive, oolong tea, orange, oregano, papaya, paprika, pennyroyal mint, peppermint, pimento, potato skin, primrose, quercetin, red clover, resveratrol, Rhizoma gastrodia (Rhizomagastrodiae, Rhodiola, Rooibos, Rooibos (red or green), Rose essential oil, Rosehips, Rosemary, Saffron, Sage, Clary sage, Sandalwood, Savory, Saw palmetto, Sceletium tortuosum, Schisandra, Silvum marianum, Skullcap, Spearmint, Spikenard, Spirulina, Slippery elm bark, High tannin sorghum bran, High tannin sorghum grain, St. John's wort, Star anise, Sumac bran, Tarragon, Terpenes, Thyme, Tisane, Turmeric, Turnera aphrodisiaca, Bearberry, Valerian, Vanilla, Viola odorata odorata), white mulberry, wild yam root, wintergreen, Withania somnifera, yacon root, yellow dock, yerba mate and yerba santa.

[0131] In some embodiments, the active ingredient comprises or is derived from one or more plants or constituents, derivatives or extracts thereof, and the plants are selected from eucalyptus, star anise, cocoa and cannabis.

[0132] When present, the botanical active ingredients are typically at a concentration of about 0.01% w / w to about 10% by weight, for example, from about 0.01% w / w, about 0.05% w / w, about 0.1% w / w or about 0.5% w / w, up to about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, or about 10%, about 11%, about 12%, about 13%, about 14% or about 15% by weight, based on the total weight of the composition.

[0133] Nicotine content In some embodiments, the active ingredient comprises a nicotine component. By "nicotine component" is meant any suitable form of nicotine (e.g., free base or salt) that results in the systemic absorption of at least a portion of the nicotine present. The source of nicotine may be different, natural or synthetic. Most preferably, the nicotine is of natural origin and is obtained as an extract from Nicotiana species (e.g., tobacco). The nicotine may have the form of an enantiomeric form, S-(-)-nicotine, R-(+)-nicotine, or a mixture of S-(-)-nicotine and R-(+)-nicotine. Most preferably, the nicotine is in the form of S-(-)-nicotine (e.g., a form that is substantially all S(-)-nicotine) or a racemic mixture that is primarily or predominantly composed of S-(-)-nicotine (e.g., a mixture that is composed of about 95 parts by weight of S-(-)-nicotine and about 5 parts by weight of R-(+)-nicotine). Most preferably, the nicotine is utilized in a substantially pure form or in an essentially pure form. Highly preferred nicotine utilized 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.

[0134] Typically, the nicotine component is selected from the group consisting of nicotine free base and nicotine salts. In some embodiments, the nicotine is in its free base form. The nicotine may be tobacco-derived (e.g., tobacco extract) or non-tobacco-derived (e.g., synthetically or otherwise obtained). In various embodiments, the impregnated substrate may include a nicotine component. In various embodiments, the impregnated substrate may not include a nicotine component. In some embodiments, the impregnated substrate may include a non-tobacco-derived nicotine component.

[0135] Typically, the nicotine component (calculated as the free base), if present, is at a concentration of at least about 0.001% by weight of the impregnated substrate, e.g., at a concentration of about 0.001% by weight to about 10% by weight of the impregnated substrate. 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% by weight, e.g., about 0.1% w / w, about 0.2% w / w, about 0.3% w / w, about 0.4% w / w, about 0.5% w / w, about 0.6% w / w, about 0.7% w / w, about 0.8% w / w, or about 0.9% w / w, 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% by weight, calculated as the free base, based on the total weight of the impregnated substrate, e.g., about 0.1% w / w to about 2.5% by weight, about 0.1% w / w to about 2.0% by weight, about 0.1% w / w to about 1.5% by weight, or about 0.1% w / w to about 1% by weight. These ranges may also be applicable to other active ingredients discussed herein.

[0136] In some embodiments, the substrate of the present disclosure can 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, for example beyond trace amounts that may be naturally present in plant material. For example, certain embodiments can 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.

[0137] Cannabinoids In some embodiments, the active ingredient comprises one or more cannabinoids. As used herein, the term "cannabinoid" refers to a class of diverse natural or synthetic chemical compounds that act on intracellular cannabinoid receptors (e.g., CB1 and CB2) to alter neurotransmitter release in the brain. Cannabinoids are cyclic molecules that exhibit certain properties, such as the ability to easily cross the blood-brain barrier. Cannabinoids can be naturally derived from plants such as cannabis (phytocannabinoids), naturally derived from animals (endocannabinoids), or artificially produced (synthetic cannabinoids). Cannabis species express at least 85 different phytocannabinoids, including 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), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabinerolic acid, cannabidiolic acid (CBDA), cannabinol propyl variants (CBNV), cannabiditriol (CBO), tetrahydrocannabinolic acid (tetrahydrocannabmolic Cannabidiol can be divided into subclasses, including tetrahydrocannabivarinic acid (THCA) and tetrahydrocannabivarinic acid (THCV A).

[0138] 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), tetrahydrocannabmolic 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. Notably, CBD has a log P value of about 6.5, which makes it insoluble in aqueous environments (e.g., saliva).

[0139] 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, e.g., cannabis, in which the active substance of interest (in this case the cannabinoid, e.g., CBD) is present at a high degree of purity, e.g., greater than 95%, greater than 96%, greater than 97%, greater than 98%, or around 99% purity.

[0140] In some embodiments, the cannabinoid is an isolate of CBD at a high degree of purity 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, for example about 0.1% or less by weight of the substrate, for example about 0.01% or less by weight of the substrate.

[0141] The selection of cannabinoids and their specific percentages that may be present in the disclosed substrates will vary depending on the desired characteristics of the substrate.

[0142] In some embodiments, the cannabinoid (e.g., CBD) is present in the substrate at a concentration of at least about 0.001% by weight of the substrate, for example, from about 0.001% to about 2% by weight of the substrate. In some embodiments, the cannabinoid (e.g., 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 (e.g., 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.

[0143] Instead of or in addition to cannabinoids, the active ingredient can include cannabinoid-like compounds, which are a class of compounds derived from plants other than cannabis that have the same biological effects on the endocannabinoid system as cannabinoids. Examples include yangonin, α-amyrin or β-amyrin (also classified as terpenes), cyanidin, curcumin (turmeric), catechin, quercetin, salvinorin A, N-acylethanolamines and N-alkylamide lipids. Such compounds can be used in the same amounts and ratios as described herein for cannabinoids.

[0144] In some embodiments, the active ingredient includes nicotine and cannabidiol (CBD). In some embodiments, the active ingredient includes nicotine, cannabidiol (CBD) and THC (tetrahydrocannabinol). In some embodiments, the active ingredient includes nicotine, caffeine, taurine, theine, vitamins such as B6 or B12, or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof.

[0145] 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 sedative effects. Terpenes have the general formula (C5H8): n Terpenes are believed to have the following structure, including monoterpenes, sesquiterpenes, and diterpenes. Terpenes can be acyclic, monocyclic, or bicyclic in structure. Some terpenes, when used in combination with cannabinoids or cannabinoid-like compounds, produce an entourage effect. Examples include β-caryophyllene, linalool, limonene, β-citronellol, linalyl acetate, pinene (α or β), geraniol, carvone, eucalyptol, menthone, iso-menthone, piperitone, myrcene, β-bourbonene, and germacrene, which can be used individually or in combination.

[0146] In some embodiments, the terpene is a terpene derivable from a plant that produces phytocannabinoids, such as a plant of the cannabis sativa species, such as cannabis. Suitable terpenes in this context include the so-called "C10" terpenes, which are terpenes containing 10 carbon atoms, and the so-called "C15" terpenes, which are terpenes containing 15 carbon atoms. In some embodiments, the active ingredient comprises more than one terpene. For example, the active ingredient may comprise one, two, three, four, five, six, seven, eight, nine, ten or more terpenes as defined herein. In some embodiments, the terpene is selected from pinene (alpha and beta), geraniol, linalool, limonene, carvone, eucalyptol, menthone, iso-menthone, piperitone, myrcene, beta-bourbonene, germacrene, and mixtures thereof.

[0147] The terpenes and / or cannabinoids may be present in the substrate as active ingredients, as aerosol forming materials, or as flavoring elements. The amount of terpenes and / or cannabinoids present may vary accordingly based on their intended purpose.

[0148] Flavoring agentIn some embodiments, the substrate comprises a flavoring agent. The flavoring agent may be a component of the aerosol-forming material or may be impregnated separately. Impregnation may be performed during preparation of the substrate material, after formation of the substrate, or both. As used herein, reference to a "flavoring agent" refers to a compound or component that can be aerosolized and delivered to a user to impart a sensory experience in terms of taste and / or aroma. The flavoring agent may be natural or synthetic, and the flavor character imparted thereby may be described as fresh, sweet, herbal, confectionery, floral, fruity, or spicy, without limitation.Some examples of flavoring agents include, but are not limited to, aloe vera, aniseed, apple, Asian spices, bacopa monniera, basil, bay leaf, shiso, bergamot, berries, betel quid, blueberry, bourbon, camphene, hemp, caraway, cardamom, calvi, cascarilla, cassia, black currant, celery, chamomile, cherry, cherry blossom, chives, cilantro, cinnamon, citrus fruits, clementine, black , cocoa, coffee, cognac, coriander, cranberry, cucumber, cumin, curcuma, damiene, dragon fruit, drambuie, durian, elderberry, eucalyptus, eugenol, fennel, fenugreek, flax, geranium, gin, ginger, ginkgo biloba, grape, guayusa, hazel, cannabis, hibiscus, honeybush, honey essence, hydrangea, Indian spices, jasmine, juniper Perilla, khat, lavender, laurel, lemon, lemongrass, lemon balm, lemon oil, lemon peel, licorice, lime, limonene, mace, oak, mango, maple, marjoram, matcha, yerba mate, menthol, mint, myrtle, mulberry, nasturtium, nutmeg, olive, orange blossom, orange oil, orange peel, oregano, papaya, paprika, peach, peppermint, green pepper, pimento, pine, rhubarb, rooibos, Rosemary, rose hips, rose oil, rum, saffron, sage, sandalwood, scotch, shisha, spearmint, strawberry, tarragon, tea, e.g., green or black tea, tequila, terpenes, thyme, tobacco, tropical fruits, turmeric, valerian, vanilla, verbena, wasabi, whiskey, wintergreen, Withania somnifera, yerba mate, yerba santa, ylang ylang, and combinations thereof.

[0149] The flavoring agent may further include flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, and trigeminal sensate agents. As used herein, "trigeminal sensate agents" refer to flavoring agents that act on the trigeminal nerve and produce sensations including heating, cooling, tingling, and the like. Non-limiting examples of trigeminal sensate flavoring agents include capsaicin, citric acid, menthol, szechuan peony, erythritol, and cubol.

[0150] Further non-limiting examples include flavoring and flavoring packages of the type and nature that are conventionally used for the flavoring of cigarettes, cigars and pipe tobacco.See also Leffingwell et al., Tobacco Flavoring for Smoking Products, RJ Reynolds Tobacco Company (1972), which is incorporated herein by reference.Flavoring agents can include, for example, terpenes, terpenoids, aldehydes, ketones, esters and other components.Syrups, for example, high fructose corn syrup, can also be utilized.Some examples of plant-derived compositions that may be suitable are disclosed in U.S. Patent No. 9,107,453 and U.S. Patent Application Publication No. 2012 / 0152265 by Dube et al., both of which are incorporated herein by reference in their entirety.The selection of such additional components varies based on factors such as the sensory properties desired for the smoking article, their affinity to the substrate material, their solubility, and other physiochemical properties. The present disclosure is intended to encompass any such additional components 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 as described above, but may in fact represent a combination of one or more flavoring agents. Additional flavoring agents, flavorings, additives and other potential enhancing components are described in U.S. Patent Application Serial No. 15 / 707,461 by Phillips et al., the entirety of which is incorporated herein by reference.

[0151] 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 from about 0.1%, about 0.5%, about 1%, or about 5% by weight to about 10%, about 20%, or about 30% by weight of the impregnated substrate.

[0152] water The moisture (e.g., water) content of the substrate may vary. For example, in some embodiments, the substrate comprises from about 0% to about 30% water. In some embodiments, the substrate is dried during preparation to remove at least a portion of the water present. In some embodiments, after drying, the substrate comprises from about 3 to about 21% water, based on the total weight of the substrate. In some embodiments, after drying, the substrate comprises from about 8 to about 10 or from about 12 to about 18% water, based on the total weight of the substrate. In some embodiments, after drying, the substrate comprises from about 15 to about 21% water, based on the total weight of the substrate.

[0153] Coloring agent In some embodiments, the substrate comprises a colorant. The addition of the colorant can change the visual appearance of the substrate. The presence of the colorant can enhance the visual appearance of the substrate and / or the aerosol generating element that includes the substrate. By adding a colorant to the substrate, the substrate can be color-matched with other components of the aerosol generating element or other components of the article that includes the substrate.

[0154] A variety of colorants can be used depending on the desired color of the substrate. The color of the substrate can be, for example, white, green, red, purple, blue, brown, or black. Other colors are also contemplated herein. Natural or synthetic colorants can be used, such as natural or synthetic dyes, food grade colorants, and pharmaceutical grade colorants. In certain embodiments, the colorant is caramel and can be imparted to the substrate having a brown appearance. In such embodiments, the color of the substrate can be similar to the color of other components (e.g., tobacco material) in the aerosol generating element that includes the substrate. In some embodiments, the addition of the colorant to the substrate makes this component visually indistinguishable from the other components. The colorant can be incorporated during formation of the substrate (e.g., when forming a slurry that includes the materials that form the substrate) or the colorant can be applied to the substrate after its formation (e.g., by spraying it onto the substrate).

[0155] Tobacco Materials In some embodiments, the substrate, or the aerosol generating element comprising the substrate, or both, comprise tobacco material. The tobacco material can vary in species, variety, and form. Typically, the tobacco material is obtained from harvested plants of the Nicotiana species. Exemplary Nicotiana species include N. tabacum, N. rustica, N. alata, N. arentsii, N. excelsior, N. forgetiana, N. glauca, N. glutinosa, N. gossei, N. kawakamii, N. kawakamiii ... akamii, N. knightiana, N. langsdorffi, N. otophora, N. setchelli, N. sylvestris, N. tomentosa, N. tomentosiformis, N. undulata, Nx sanderae sanderae, N. africana, N. amplexicaulis, N. benavidesii, N. bonariensis, N. debneyi, N. longiflora, N. maritina, N. megalosiphon, N. occidentalis, N. paniculata lata, N. plumbaginifolia, N. raimondii, N. rosulata, N. simulans, N. stocktonii, N. suaveolens, N. umbratica, N. velutina, N. wigandioides, N. acaulis, N.N. acuminata, N. attenuata, N. benthamiana, N. cavicola, N. clevelandii, N. cordifolia, N. corymbosa, N. fragrans, N. goodspeedii, N. linearis, N. miersii, N. nudicaulis, N. obtusifolia, N. occidentalis subsp. hesperis subsp. Hersperis, N. pauciflora, N. petunioides, N. quadrivalvis, N. repanda, N. rotundifolia, N. solanifolia and N. spegazzinii. Various representative other types of plants from the species Nicotiana are described in Goodspeed, The Genus Nicotiana, (Chonica Botanica) (1954); U.S. Patent Nos. 4,660,577 to Sensabaugh, Jr. et al.; 5,387,416 to White et al.; 7,025,066 to Lawson et al.; 7,798,153 to Lawrence, Jr. and 8,186,360 to Marshall et al., each of which is incorporated herein by reference. Descriptions of various types of tobacco, growing practices and harvesting practices are found in Tobacco Production, Chemistry and Technology, Davis et al. (eds.) (1999), which is incorporated herein by reference.

[0156] Nicotiana species from which suitable tobacco material can be obtained can be derived using genetic modification or cross-breeding techniques (e.g., tobacco plants can be genetically engineered or cross-bred to increase or decrease the production of a component, characteristic or trait). See, for example, the types of genetic modifications of plants described in U.S. Patent Nos. 5,539,093 to Fitzmaurice et al.; 5,668,295 to Wahab et al.; 5,705,624 to Fitzmaurice et al.; 5,844,119 to Weigl; 6,730,832 to Dominguez et al.; 7,173,170 to Liu et al.; 7,208,659 to Colliver et al. and 7,230,160 to Benning et al.; U.S. Patent Application Publication No. 2006 / 0236434 to Conkling et al.; and PCTWO2008 / 103935 to Nielsen et al. See also the types of tobacco described in U.S. Patents 4,660,577 to Sensabaugh, Jr. et al.; 5,387,416 to White et al.; and 6,730,832 to Dominguez et al., each of which is incorporated herein by reference.

[0157] Nicotiana species can be selected in some embodiments for the content of various compounds present therein. For example, plants can be selected based on the fact that they produce relatively high amounts of one or more desired compounds to be isolated from these plants. In certain embodiments, Nicotiana species (e.g., Nicotiana galpaocomun) plants are specifically grown for their high amounts of these leaf surface compounds. Tobacco plants can be grown outdoors in greenhouses, growth chambers, or fields, or grown hydroponically.

[0158] Various parts or portions of a plant of a Nicotiana species may be included within the substrates disclosed herein. For example, substantially all of the plant (e.g., the entire plant) may be harvested and utilized as is. Alternatively, various parts or pieces of the plant may be harvested or separated for further use after harvest. For example, flowers, leaves, stems, stalks, roots, seeds, and various combinations thereof may be isolated for further use or processing. In some embodiments, the tobacco material comprises tobacco leaf (lamina). The substrates disclosed herein may comprise processed tobacco parts or pieces, cured and aged tobacco in essentially natural lamina and / or stem form. In certain embodiments, the tobacco material comprises a solid tobacco material selected from the group consisting of lamina and stem. The tobacco used for the substrate most preferably comprises tobacco lamina or a mixture of tobacco lamina and stem, at least a portion of which is smoked. The tobacco portion can have a processed form, such as processed tobacco stems (e.g., cut rolled stems, cut rolled expanded stems, or cut expanded stems) or volume expanded tobacco (e.g., expanded tobacco, e.g., dry ice expanded tobacco (DIET)). See, for example, the tobacco expansion methods described in U.S. Pat. Nos. 4,340,073 to de la Burde et al.; 5,259,403 to Guy et al.; and 5,908,032 to Poindexter et al.; and 7,556,047 to Poindexter et al., all of which are incorporated by reference. In addition, the substrate can also incorporate fermented tobacco. See also the types of tobacco processing techniques described in PCT WO 2005 / 063060 to Atchley et al., which is incorporated by reference herein.

[0159] Tobacco materials are typically used in a form that can be described as particulate, such as shredded, ground, granulated, pulp, or powder form. In some embodiments, tobacco materials are utilized in the form of pieces or pieces having an average particle size between 1.4 millimeters and 250 microns. In some cases, the tobacco particles can be sized to pass through a screening mesh to obtain the required particle size range. If desired, air classifiers can be used to ensure that small sized tobacco particles of the desired size or size range are collected. Granulated tobacco pieces of different sizes can be mixed together if desired.

[0160] The manner in which the tobacco material is provided in a finely divided or powder-type form may vary. Preferably, the plant parts or pieces are milled, comminuted, crushed or pulverized into a particulate form using equipment and techniques for grinding, milling, etc. The plant, or parts thereof, may be subjected to an external force or pressure (e.g., by being compressed or subjected to a rolling process). When performing such processing conditions, the plant or parts thereof may have a moisture content that approximates its natural moisture content (e.g., its moisture content immediately upon harvesting), a moisture content achieved by adding moisture to the plant or parts thereof, or a moisture content resulting from drying the plant or parts thereof. For example, powdered, comminuted, crushed, pulped or milled plant pieces or parts thereof may have a moisture content of less than about 25 weight percent, often less than about 20 weight percent and frequently less than about 15 weight percent. Most preferably, the plant material is in a relatively dry form during grinding or milling using equipment such as hammer mills, cutter heads, air-conditioned mills, etc. For example, the tobacco portions or pieces can be ground or milled when their moisture content is less than about 15 percent by weight, or less than about 5 percent by weight.

[0161] For the preparation of the substrate, it is typical to subject harvested plants of Nicotiana species to a drying process. The tobacco material incorporated into the substrate disclosed herein is generally a material that has been properly cured and / or aged. A description of different types of curing processes for different types of tobacco is provided in Tobacco Production, Chemistry and Technology, Davis et al. (eds.) (1999). Examples of techniques and conditions for curing flue-cured tobacco are provided in Nestor et al., Beitrage Tabakforsch.Int., Vol. 20, pp. 467-475 (2003) and U.S. Patent No. 6,895,974 by Peele, which are incorporated herein by reference. Exemplary techniques and conditions for air-curing tobacco are described in U.S. Patent No. 7,650,892 to Groves et al.; Roton et al., Beitrage Tabakforsch. Int., Vol. 21, pp. 305-320 (2005) and Staaf et al., Beitrage Tabakforsch. Int., Vol. 21, pp. 321-330 (2005), which are incorporated herein by reference. Certain types of tobacco can be subjected to alternative types of curing processes, such as flame-curing or sun-curing.

[0162] In certain embodiments, tobacco materials that may be utilized include flue-cured or Virginia (e.g., K326), Burley, sun-cured (e.g., Indian Kurnool and Oriental tobaccos, including Katerini, Pre-lip, Komotini, Xanthi, and Yambol tobaccos), Maryland, dark, dark-fired, dark air-cured (e.g., Madol, Pasanda, Cubano, Jatin, and Bezuki tobaccos), light air-cured (e.g., North Wisconsin and Galpao tobaccos), Indian air-cured, Red Russian, and Rustic tobaccos, as well as various other rare or specialty tobaccos and various blends of any of the aforementioned tobaccos.

[0163] The tobacco material can also have a so-called "blended" form. For example, the tobacco material can include a mixture of flue-cured, burley (e.g., Malawi Burley) and oriental tobacco parts or pieces (e.g., tobacco composed of or derived from tobacco lamina, or a mixture of tobacco lamina and tobacco stem). For example, a representative blend can incorporate, on a dry weight basis, about 30 parts to about 70 parts burley tobacco (e.g., lamina or lamina and stem) and about 30 parts to about 70 parts flue-cured tobacco (e.g., stem, lamina or lamina and stem). Other exemplary tobacco blends incorporate, on a dry weight basis, about 75 parts flue-cured tobacco, about 15 parts burley tobacco and about 10 parts oriental tobacco; or about 65 parts flue-cured tobacco, about 25 parts burley tobacco and about 10 parts oriental tobacco; or about 65 parts flue-cured tobacco, about 10 parts burley tobacco and about 25 parts oriental tobacco. Other exemplary tobacco blends incorporate, on a dry weight basis, from about 20 parts to about 30 parts Oriental tobacco and from about 70 parts to about 80 parts flue-cured tobacco.

[0164] The tobacco material used in the present disclosure can be subjected to, for example, fermentation, bleaching, etc. If desired, the tobacco material can be subjected to, for example, irradiation, pasteurization, or other controlled heat treatment. Such treatment processes are detailed, for example, in U.S. Patent No. 8,061,362 to Mua et al., which is incorporated herein by reference. In certain embodiments, the tobacco material can be treated with water and additives capable of inhibiting the reaction of asparagine to form acrylamide upon heating of the tobacco material (e.g., additives selected from the group consisting of lysine, glycine, histidine, alanine, methionine, cysteine, glutamic acid, aspartic acid, proline, phenylalanine, valine, arginine, compositions incorporating divalent and trivalent cations, asparaginase, certain non-reducing sugars, certain reducing agents, phenolic compounds, certain compounds having at least one free thiol group or functional group, oxidizing agents, oxidation catalysts, natural plant extracts (e.g., rosemary extract), and combinations thereof). See, for example, the types of treatment processes described in U.S. Patent Publication Nos. 8,434,496, 8,944,072, and 8,991,403 to Chen et al., all of which are incorporated herein by reference. In certain embodiments, this type of treatment is useful when the original tobacco material is subjected to heat in the previously described processes.

[0165] In some embodiments, a type of tobacco material is selected whose color is initially visually somewhat lighter than other tobacco materials (e.g., whitened or bleached). The tobacco pulp can be whitened according to any means known in the art in certain embodiments. For example, bleached tobacco materials produced by various whitening methods using various bleaching or oxidizing agents and oxidation catalysts can be used. Exemplary oxidizing agents include peroxides (e.g., hydrogen peroxide), chlorites, chlorates, perchlorates, hypochlorites, ozone, ammonia, potassium permanganate, and combinations thereof. Exemplary oxidation catalysts are titanium dioxide, manganese dioxide, and combinations thereof.Methods for treating tobacco with bleaching agents are described, for example, in U.S. Patents Nos. 787,611 to Daniels, Jr.; 1,086,306 to Oelenheinz; 1,437,095 to Delling; 1,757,477 to Rosenhoch; 2,122,421 to Hawkinson; 2,148,147 to Baier; 2,170,107 to Baier; 2,274,649 to Baier; and 2,770,237 to Pratz et al., all of which are incorporated herein by reference. No. 9; No. 3,612,065 by Rosen; No. 3,851,653 by Rosen; No. 3,889,689 by Rosen; No. 3,943,940 by Minami; No. 3,943,945 by Rosen; No. 4,143,666 by Rainer; No. 4,194,514 by Campbell; Nos. 4,366,823, 4,366,824, and 4,388,933 by Rainer et al.; No. 4,641,667 by Schmekel et al.; No. 5,713,376 by Berger; No. 9,339,058 by Byrd Jr. et al.; Nos. 9,420,825 and 10,772,349 by Beeson et al.; and No. 10,772,349 by Byrd. No. 9,950,858 by Jr. et al.; and U.S. Patent Application Publication Nos. 2012 / 0067361 by Bjorkholm et al.; 2016 / 0073686 by Crooks; 2017 / 0020183 by Bjorkholm; and 2017 / 0112183 by Bjorkholm, as well as PCT Patent Application Publication No. WO1996 / 031255 by Giolvas; WO2020128971 and WO2021048769 by McClanahan et al.; WO2013122948A1 by Beeson et al.; WO2018 / 083114 by Bjorkholm; and WO2021048768 and WO2021048770A1 by Zawadzki et al.

[0166] In some embodiments, the whitened tobacco material can have an ISO brightness of at least about 50%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, or at least about 80%. In some embodiments, the whitened tobacco material can have an ISO brightness in the range of about 50% to about 90%, about 55% to about 75%, or about 60% to about 70%. ISO brightness can be measured according to ISO 3688:1999 or ISO 2470-1:2016.

[0167] In some embodiments, a whitened tobacco material can be characterized by a lighter color (e.g., "whitened") compared to an untreated tobacco material. White color is often defined with reference to the International Commission on Illumination's (CIE's) chromaticity diagram. A whitened tobacco material can, in certain embodiments, be characterized as being closer to pure white on the chromaticity diagram than an untreated tobacco material.

[0168] The tobacco material may also be processed to remove at least a portion of the nicotine present. Suitable methods for extracting nicotine from tobacco materials are known in the art. In some embodiments, the tobacco material is substantially free of nicotine. By "substantially free" it is meant that only trace amounts are present in the tobacco material. For example, in certain embodiments, the tobacco material 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 the free base, based on the total mass of the tobacco material.

[0169] The amount of tobacco material present may vary and is generally less than about 65% by weight of the substrate, based on the total weight of the substrate. For example, the tobacco material may be present in an amount from about 0%, about 0.1%, about 0.5%, about 1%, about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, or about 35% by weight of the substrate, up to about 40%, about 45%, about 50%, about 55%, about 60%, or about 65% by weight of the substrate, based on the total dry weight of the substrate.

[0170] In some embodiments, the substrate of the present disclosure may be characterized as being completely free or substantially free of any tobacco material (e.g., any embodiment disclosed herein may be completely or substantially free of any tobacco material). By "substantially free" it is meant that no tobacco material has been intentionally added beyond trace amounts that may be naturally present, for example, in plants or herbal materials. For example, certain embodiments may be characterized as having less than 0.5% tobacco material, less than 0.1% tobacco material, less than 0.01% tobacco material, or less than 0.001% or even 0% tobacco material by weight based on the total wet weight of the substrate.

[0171] Tobacco-derived materials In some embodiments, the substrate further comprises a tobacco extract, e.g., an aqueous tobacco extract, added as a component of the aerosol-forming material or added separately (e.g., during preparation of the substrate or impregnated into the substrate after formation). "Tobacco extract" as used herein refers to an isolated component of tobacco material that is extracted from solid tobacco pulp by a solvent (e.g., water) that is contacted with the tobacco material in an extraction process. Various extraction techniques of tobacco material can be used to obtain tobacco extracts and tobacco solids. See, for example, the extraction process described in U.S. Patent Application Publication No. 2011 / 0247640 by Beeson et al., which is incorporated herein by reference.Other exemplary techniques for extracting tobacco components include U.S. Patent 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; 4,589,428 to Keritsis; all of which are incorporated herein by reference. No. 4,605,016 by Soga et al.; No. 4,716,911 by Poulose et al.; No. 4,727,889 by Niven, Jr. et al.; No. 4,887,618 by Bernasek et al.; No. 4,941,484 by Clapp et al.; No. 4,967,771 by Fagg et al.; No. 4,986,286 by Roberts et al.; No. 5,005,593 by Fagg et al.; No. 5,018,540 by Grubbs et al.; No. 5,060,669 by White et al.; No. 5,020,593 by Fagg et al. No. 5,065,775 by White et al.; No. 5,074,319 by White et al.; No. 5,099,862 by White et al.; No. 5,121,757 by White et al.; No. 5,131,414 by Fagg; No. 5,131,415 by Munoz et al.; No. 5,148,819 by Fagg; No. 5,197,494 by Kramer; No. 5,230,354 by Smith et al.; No. 5,234,008 by Fagg; No. 5,243,999 by Smith; No. 5,243,999 by Raymond et al. Nos. 5,301,694 by Gonzalez-Parra et al.; 5,318,050 by Teague; 5,343,879 by Newton; 5,360,022 by Newton; 5,435,325 by Clapp et al.; 5,445,169 by Brinkley et al.; 6,131,584 by Lauterbach; 6,298,859 by Kierulff et al.; 6,772,767 by Mua et al.; and 7,337,782 by Thompson.

[0172] Acid composition In some embodiments, the substrate comprises an acid component. The presence of either an acid component or an acid salt of nicotine in the substrate can improve the sensory attributes of the aerosol, for example, by reducing the harshness of nicotine when present in the substrate. If present, the acid, once formed, protonates nicotine to form a nicotine salt in situ, either in the substrate or in the aerosol. The presence of a nicotine salt results in an aerosol that is more satisfying to some users. Additionally, the presence of an acid can reduce or substantially prevent the evaporation of nicotine during preparation of the substrate (e.g., during drying), thereby reducing the loss of nicotine during manufacture.

[0173] The amount of acid present in the substrate may vary, such as, for example, from 0% to about 20% by weight based on the dry weight of the substrate. In some embodiments, the substrate comprises an acid in a molar ratio to nicotine. In some embodiments, the molar ratio of nicotine to acid is 2.2:1 or less, such as 1.5:1 or less, or 1:1 or less. In some embodiments, the molar ratio of nicotine to acid is 0.5:1 or greater.

[0174] In some embodiments, the acid comprises an acidic functional group having a pKa value, measured at 25° C., in the range of about 2 to about 6, e.g., a pKa value in the range of 3 to 6 or 4 to 5. In some embodiments, the acid can be a monobasic acid, a dibasic acid, a tribasic acid, or a combination thereof.

[0175] In some embodiments, the acid is an organic acid. In some embodiments, the organic acid is a carboxylic acid. In some embodiments, the carboxylic acid comprises at least one carboxyl functional group. In some embodiments, the carboxylic acid is a monocarboxylic acid, a dicarboxylic acid, or a tricarboxylic acid. In some embodiments, the carboxylic acid further comprises an alpha hydroxy group. In some embodiments, the carboxylic acid further comprises a keto group.

[0176] In some embodiments, the carboxylic acid is selected from the group consisting of succinic acid, lactic acid, benzoic acid, citric acid, tartaric acid, fumaric acid, levulinic acid, acetic acid, malic acid, formic acid, sorbic acid, benzoic acid, propanoic acid, pyruvic acid, and combinations thereof. In some embodiments, the carboxylic acid is lactic acid. In some embodiments, the carboxylic acid is benzoic acid.

[0177] In other embodiments, the acid is an inorganic acid. In some embodiments, the inorganic acid is a mineral acid, such as sulfuric acid, hydrochloric acid, boric acid, phosphoric acid, or a combination thereof.

[0178] Other components In some embodiments, the substrate may further include flame retardant materials, conductive fibers or particles for thermal conduction / induction heating, or any combination thereof. One example of a flame retardant material is ammonium phosphate. In some embodiments, other flame / flame retardant materials and additives may be included within the substrate, including organo-phosphorus compounds, borax, hydrated alumina, graphite, potassium, silica, tripolyphosphates, dipentaerythritol, pentaerythritol, and polyols. Other flame retardant materials, such as nitrogenous phosphonates, monoammonium phosphates, ammonium polyphosphates, ammonium bromide, ammonium borate, ethanolammonium borate, ammonium sulfamate, halogenated organic compounds, thiourea, and antimony oxide, may also be used. Each aspect of the flame retardant, flame retardant, and / or scorch retardant materials used in the substrate material and / or other components (whether alone or in combination with each other and / or other materials) is independent of the desired properties and is resistant to undesirable off-gassing or melting type behavior. Various modes and methods for incorporating tobacco into smoking articles, particularly smoking articles configured to intentionally not combust substantially all of the tobacco within the smoking articles, are described in U.S. Pat. No. 4,947,874 to Brooks et al.; U.S. Pat. No. 7,647,932 to Cantrell et al.; U.S. Pat. No. 8,079,371 to Robinson et al.; U.S. Pat. No. 7,290,549 to Banerjee et al.; and U.S. Patent Application Publication No. 2007 / 0215167 to Crooks et al., the disclosures of which are incorporated by reference in their entireties.

[0179] The substrate may also include conductive fibers or particles for thermal conduction or induction heating. In some embodiments, the conductive fibers or particles may be arranged in a substantially linear and parallel pattern. In some embodiments, the conductive fibers or particles may also have a substantially random arrangement. In some embodiments, the conductive fibers or particles may be constructed of one or more of aluminum, stainless steel, copper, carbon, and graphite materials. In some embodiments, one or more conductive fibers or particles having different Curie temperatures may be included in the substrate material to facilitate induction heating at different temperatures.

[0180] In yet other implementations, the substrate material can include various types of inorganic fibers (e.g., fiberglass, metal wires / screens, etc.) and / or (organic) synthetic polymers. In various implementations, these "fibrous" materials can be unstructured (e.g., randomly distributed) or structured (e.g., wire mesh) materials.

[0181] Substrate morphology The substrate may be in different forms, for example, the substrate may be in the form of a powder, dust, particles, granules, pellets, pieces, strips, sheets, films, etc. In some embodiments, the substrate is in shredded form, film form, paper form, or cast sheet form.

[0182] In some embodiments, the substrate is in the form of a cast sheet. In some embodiments, the cast sheet is in the form of a flat sheet. In some embodiments, the cast sheet has a thickness of about 0.015 mm to about 1.0 mm. Suitably, the thickness may range from about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm, for example 0.1-3 mm or 0.15-3 mm. Sheets having a thickness of 0.2 mm may be particularly suitable. The thicknesses specified herein are average thicknesses for the sheets. In some cases, the thickness of the sheets may vary by no more than 25%, 20%, 15%, 10%, 5% or 1%.

[0183] In some embodiments, the flat sheet forms are layered in a series of overlapping layers 130 of flat sheet forms 120, for example, as illustrated in Figures 4 and 5. In some embodiments, the flat sheet forms may be bundled, rolled, crimped and / or otherwise collected layers. In some embodiments, the flat sheet forms may be further reduced into chopped lugs or strips for insertion into a substrate-containing segment of an aerosol delivery device. The flat sheet forms may also be collected or rolled into a rod for insertion into a substrate-containing segment of an aerosol delivery device. In some embodiments, the substrate is formed into a substantially cylindrical shape. In some embodiments, the flat sheet forms may be chopped. Although substrates in sheet form are advantageous in the present disclosure, other forms may be utilized in certain embodiments, such as beaded, chopped or particulate forms.

[0184] In some embodiments, the individual strips or pieces of substrate have a minimum thickness of about 0.015 mm over their area. In some cases, the individual strips or pieces of substrate have a minimum thickness of about 0.05 mm or about 0.1 mm over their area. In some cases, the individual strips or pieces of substrate have a maximum thickness of about 1.0 mm over their area. In some cases, the individual strips or pieces of substrate have a maximum thickness of about 0.5 mm or about 0.3 mm over their area.

[0185] In some examples, the substrate in sheet form may have a tensile strength of about 150 N / m to about 3000 N / m, e.g., 150 N / m to 2500 N / m, or 150 N / m to 2000 N / m, or 200 N / m to 1700 N / m, or 250 N / m to 1500 N / m, or 200 N / m to 900 N / m. In some embodiments, the substrate may have a tensile strength of 150 N / m to 500 N / m, or 200 N / m to 400 N / m, or 200 N / m to 300 N / m, or about 250 N / m. Such tensile strengths may be particularly suitable for embodiments in which the substrate is formed as a sheet and then chopped and incorporated into an aerosol generating element.

[0186] In some embodiments, the substrate may have a tensile strength of 150 N / m to 3000 N / m, e.g., 500 N / m to 1200 N / m, or 600 N / m to 900 N / m, or 700 N / m to 900 N / m, or about 800 N / m, or greater. In some examples, the substrate may have a tensile strength of greater than 500 N / m, greater than 1000 N / m, or greater than 1500 N / m. Such tensile strengths may be particularly suitable for embodiments in which the substrate is included in the aerosol generation element as a rolled up sheet, suitably in the form of a tube.

[0187] In some embodiments, the substrate is formed as a sheet and then cut into smaller pieces, such as particles or fragments. Substrate materials in such forms can be mixed with other materials, if desired, to form blends, such as mixtures with finely shredded or particulate tobacco materials or other non-tobacco substrate materials.

[0188] Preparation of cast sheets In some embodiments, cast sheet technology can be used to produce a substrate in the form of a flat sheet type. The cast sheet generally comprises one or more fillers, one or more binders, optionally one or more aerosol-forming substances, and optionally active ingredients, flavorings, or both, each as described herein. For example, in some embodiments, the filler, at least a portion of the aerosol-forming material disclosed herein, and the binder can be blended together to form a slurry, and the slurry can be cast onto a surface (e.g., a moving belt). The cast slurry can then be applied to one or more drying and / or mixing steps, resulting in a cast sheet of relatively consistent thickness. Other examples of casting and paper making techniques are described in U.S. Pat. No. 4,674,519 to Keritsis et al.; U.S. Pat. No. 4,941,484 to Clapp et al.; U.S. Pat. No. 4,987,906 to Young et al.; U.S. Pat. No. 4,972,854 to Kiernan et al.; U.S. Pat. No. 5,099,864 to Young et al.; U.S. Pat. No. 5,143,097 to Sohn et al.; U.S. Pat. No. 5,159,942 to Brinkley et al.; U.S. Pat. No. 5,322,076 to Brinkley et al.; U.S. Pat. No. 5,339,838 to Young et al.; U.S. Pat. No. 5,377,698 to Litzinger et al.; U.S. Pat. No. 5,501,237 to Young; and U.S. Pat. No. 6,216,706 to Kumar, the disclosures of which are incorporated herein by reference in their entireties. In some embodiments, the flat sheet form may be further reduced into a scored lug or strip for insertion into a substrate-containing segment of an aerosol delivery device. The cast sheet may also be collected or rolled into a rod for insertion into a substrate-containing segment of an aerosol delivery device. The cast sheet may be adhered or otherwise attached to a support.

[0189] The various components of the substrate can be contacted, combined, or mixed together using any mixing technique or device known in the art. Any mixing method that brings the substrate components into intimate contact can be used, such as a mixing device with an impeller or other structure capable of stirring. Examples of mixing devices include casing drums, conditioning cylinders or drums, liquid spray devices, conical type blenders, ribbon blenders, mixers available from Littleford Day, Inc. as FKM130, FKM600, FKM1200, FKM2000 and FKM3000, Plough Share type mixer cylinders, Hobart mixers, and the like. See also, for example, the types of methodologies described in U.S. Patents 4,148,325 to Solomon et al.; 6,510,855 to Korte et al.; and 6,834,654 to Williams, each of which is incorporated herein by reference. The manner and method for formulating the mixture will be clear to those skilled in the art. See, for example, the types of methodologies described in U.S. Pat. Nos. 4,148,325 to Solomon et al.; 6,510,855 to Korte et al.; and 6,834,654 to Williams, 4,725,440 to Ridgway et al., and 6,077,524 to Bolder et al., each of which is incorporated herein by reference.

[0190] The sheet can be optionally dried to remove at least a portion of the liquid content (e.g., water). The final moisture content can be about 8 to about 21% moisture by weight on a wet basis. Additionally, flavors, extracts, aerosol forming materials, and the like can be added to the sheet after drying.

[0191] Filling of the substrate In various embodiments, loading of 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. In some embodiments, for example, the slurry used to prepare the cast sheet includes the entire amount of the aerosol-forming material. Alternatively, or in addition, a portion of the aerosol-forming material may be added to the substrate after formation (e.g., one or more aerosol-forming materials may be sprayed or otherwise disposed in sheet form on or in the substrate material). In some embodiments, additional aerosol-forming material may be impregnated into the substrate in the substrate forming slurry or as a top finish. Methods for loading aerosol-forming material into substrate portions are described in U.S. Pat. No. 9,974,334 to Dooly et al. and U.S. Patent Application Publication No. 2015 / 0313283 to Collett et al. and U.S. Patent Application Publication No. 2018 / 0279673 to Sebastian et al., the disclosures of which are incorporated herein by reference in their entireties. Those skilled in the art will recognize that multiple permutations of the method for loading the substrate with the aerosol-forming material are possible depending on the particular substrate material, morphology, etc. Accordingly, any such modifications are contemplated herein.

[0192] Aerosol generating elements and aerosol delivery devices The substrate according to certain embodiments of the present disclosure can be used in an aerosol delivery device or its aerosol generating element.Accordingly, a further exemplary embodiment of the present disclosure relates to an aerosol delivery device comprising an aerosol generating element comprising a substrate as disclosed herein; a heat source configured to heat an aerosol-forming material carried in the substrate portion to form an aerosol; and an aerosol path extending from the aerosol generating element to the mouth end of the aerosol delivery device.The individual components and constructions of the aerosol generating element and the aerosol delivery device are provided herein below.

[0193] The aerosol generating elements of certain exemplary aerosol delivery devices can provide many of the sensations of smoking a cigarette, cigar, or pipe (e.g., the ritual of inhalation and exhalation, the variety of tastes or flavors, the organoleptic effects, the physical feel, the ritual of use, visual cues, such as those provided by a visible aerosol, etc.) obtained by lighting and burning tobacco (and thus inhaling tobacco smoke), without any substantial degree of combustion of any of the elements. For example, a user of an aerosol delivery device according to some exemplary embodiments of the present disclosure can hold and use the components in much the same way that a smoker would use a traditional type of smoking article, and can take in a puff or draw in at a selected time interval, etc., utilizing one end of the piece for inhalation of the aerosol generated by the piece.

[0194] Although the present system is generally described herein in terms of embodiments relating to aerosol delivery devices and / or aerosol generating elements, e.g., so-called "e-cigarettes" or "heated tobacco products," it should be understood that the mechanisms, components, features, and methods may be embodied in many different forms and associated with a variety of articles. For example, the description provided herein may be utilized in conjunction with traditional smoking articles (e.g., cigarettes, cigars, pipes, etc.), heated tobacco products, and associated packaging embodiments for any of the products disclosed herein. Thus, it should be understood that the description of the mechanisms, components, features, and methods disclosed herein is discussed by way of example only in terms of embodiments relating to aerosol delivery devices, and may be embodied and used in a variety of other products and methods.

[0195] The aerosol delivery device and / or aerosol generating element of the present disclosure may also be characterized as a vapor product or pharmaceutical delivery article. Thus, such articles or devices may be adapted to provide one or more substances (e.g., flavors and / or pharma- ceutical active ingredients) in an inhalable form or state. For example, the inhalable substance may be substantially in vapor form (i.e., a substance in the gas phase at a temperature below its critical point). Alternatively, the inhalable substance may be in the form of an aerosol (i.e., a suspension of fine solid particles or liquid droplets in a gas). For brevity, the term "aerosol" as used herein is intended to include vapors, gases, and aerosols in any form or type suitable for human inhalation, whether or not visible and in a form that can be considered similar to smoke. The physical form of the inhalable 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 the inhalable substance itself as to whether it exists in a vapor or aerosol state. In some embodiments, the terms "vapor" and "aerosol" may be interchangeable. Thus, for clarity, the terms "vapor" and "aerosol" are considered interchangeable when used to describe aspects of the present disclosure, unless otherwise stated.

[0196] More specific formats, configurations and arrangements of the various substrate materials, aerosol generating elements and components within the aerosol delivery device of the present disclosure will become apparent in light of the further disclosure provided hereinafter. Furthermore, the selection of the various aerosol delivery device components is recognized in light of commercially available electronic aerosol delivery devices. Furthermore, the arrangement of the components within the aerosol delivery device is also recognized in light of commercially available electronic aerosol delivery devices.

[0197] Substrates according to certain embodiments of the present disclosure can be used in aerosol generating elements (e.g., segments) of heated-not-burn (HNB) devices that use an ignitable heat source to heat a material (generally without burning the material to any significant extent) to form an inhalable substance (e.g., a carbon-heated tobacco product). The material is typically heated without burning the material to any significant extent. See, for example, U.S. Patent Application Publication No. 2017 / 0065000 to Sears et al.; U.S. Patent Application No. 2015 / 0157052 to Ademe et al.; U.S. Patent No. 10,314,330 to Conner et al.; No. 9,345,268 to Stone et al.; No. 9,149,072 to Conner et al.; Nos. 5,105,831 and 5,042,509, both to Banerjee et al., each of which is incorporated herein by reference. Components of such systems have the form of articles small enough to be considered handheld devices. That is, the use of certain exemplary aerosol delivery device components does not result in the production of smoke, in the sense that aerosol is generated primarily from by-products of tobacco combustion or pyrolysis, but rather the use of these systems results in the production of vapor from the volatilization or evaporation of certain components incorporated therein.

[0198] Thus, in some embodiments, the aerosol generating element of the present disclosure may generally include an ignitable heat source configured to heat a substrate material as disclosed herein and aerosolize an aerosol-forming material associated with the substrate material to form an inhalable substance. At least a portion of the substrate material and / or heat source may be enclosed in an outer wrapper or envelope, casing, part, module, member, etc. The overall configuration of the enclosure may vary, as may the format or configuration of the enclosure that defines the overall size and shape of the aerosol generating element. While other configurations are possible, in some aspects it may be desirable for the overall configuration, size and / or shape of these embodiments to be similar to that of a traditional cigarette or cigar.

[0199] Substrates according to certain embodiments of the present disclosure can be used in aerosol generating elements of aerosol delivery devices that use electrical energy to heat the substrate material disclosed herein and aerosolize the aerosol-forming material associated with the substrate material to form a substance for inhalation (e.g., electrically heated tobacco products). In some exemplary embodiments, the aerosol delivery device can be characterized as an electronic cigarette. Thus, in some embodiments, the aerosol delivery device of the present disclosure can include some combination of an energy source (e.g., a power supply), at least one control element (e.g., a means for activating, controlling, regulating, and stopping the power for heat generation by controlling the current from the energy 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 electrically resistive heating element or other component and / or an inductive coil or other associated component and / or one or more radiative heating elements) and an aerosol generating element including a substrate portion disclosed herein, which can generate an aerosol upon application of sufficient heat. It is noted that one or more of the components described above can be physically combined. For example, in certain embodiments, conductive heater traces can be printed onto the surface of a substrate material as described herein using conductive inks (e.g., sheets or films) such that the heater traces can be activated by an energy source and used as resistive heating elements. Exemplary 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 can be printed onto a surface using processes such as, for example, gravure printing, flexography, offset printing, screen printing, inkjet printing, or other suitable printing methods.

[0200] In various embodiments, some of these components may comprise an exterior body or shell, which in some embodiments may be referred to as a housing. The overall configuration of the exterior body or shell may vary, and the format or configuration of the exterior body may vary, which may define the overall size and shape of the aerosol delivery device. In some embodiments, the elongated body may be formed from one, single housing, resembling the shape of a cigarette or cigar, 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 include an elongated shell or body that is substantially tubular in shape and thus may resemble the shape of a traditional 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 include two or more housings that are joined and separable. For example, an aerosol delivery device may have a control unit at one end that includes a housing containing one or more reusable components (e.g., an accumulator, e.g., a rechargeable battery and / or a rechargeable supercapacitor and various electronics for controlling the operation of the article) and an outer casing or shell at the other end that contains a disposable portion (e.g., a disposable flavor-containing aerosol generating element) that is removably connectable thereto.

[0201] Aerosol generating elements and aerosol delivery devices that include a substrate as disclosed herein and use heat from combustion or electrical energy can further include additional materials, such as, for example, tobacco materials, tobacco-derived materials, e.g., mixed with the substrate, which are referred to herein as "aerosol-generating materials." Such aerosol generating elements can also be referred to herein as "consumables," which refer to articles that include or consist of a substrate as described herein, some or all of which are intended to be consumed by a user during use.

[0202] In some embodiments, the aerosol generating element comprises a substrate as disclosed herein in the form of a sheet or in the form of a piece. In some embodiments, the aerosol generating element further comprises an aerosol-generating material, such as a tobacco material or a tobacco-derived material. In some embodiments, the aerosol-generating material is a tobacco material in the form of strips or particles, which is blended with the substrate. In some embodiments, both the substrate and the tobacco material are in the form of strips. In some embodiments, the substrate is in a layered form, comprising multiple sheets (layers) of substrate.

[0203] In some embodiments, the aerosol generating element further comprises a support. In some embodiments, the substrate is attached or adhered to the support. In some embodiments, the support is flat. A non-limiting embodiment of an aerosol generating element comprising a support and having a substrate attached or adhered thereto is illustrated in Figure 1. Referring to Figure 1, the aerosol generating element 10 comprises a support 20 and a substrate 30 disposed thereon.

[0204] The support 20 may be at least partially porous in the area of ​​its surface adjacent to the substrate 30. Conversely, the surface of the support 20 facing away from the substrate 30 may be placed in contact with a heat source as described herein. In some embodiments, the support 20 may be a laminated structure. For example, the support 20 may include a foil as a backing for a cardboard, where the cardboard layer is adjacent to the substrate 30. The foil backing is substantially impermeable and provides control of the aerosol flow path. The metal foil backing may also function to conduct heat to the substrate 30. In some embodiments, the foil layer of the foil as a backing for the cardboard is adjacent to the substrate 30. The foil is substantially impermeable, thus preventing moisture in the substrate 30 from being absorbed by the cardboard. Such absorption of moisture may weaken its structural integrity. In some embodiments, the support 20 is formed from or includes a metal foil, e.g., aluminum foil. The metal support may allow for improved conduction of thermal energy to the substrate. Additionally or alternatively, the metal foil can function as a susceptor in an induction heating system. In certain embodiments, the support 20 includes a metal foil layer and a support layer, such as cardboard. In these embodiments, the metal foil layer can have a thickness of less than 20 μm, such as from about 1 μm to about 10 μm, suitably about 5 μm.

[0205] Aerosol generating elements and aerosol delivery devices that include the substrates disclosed herein and use heat from combustion or electrical energy to provide an aerosol are further described herein below with reference to Figures 2-7.

[0206] In this regard, FIG. 2 illustrates an aerosol delivery device 100 according to an exemplary embodiment of the present disclosure. The aerosol delivery device 100 can include a controller 102 and an aerosol generating element 104. In some embodiments, the aerosol generating element is configured for use in a conductive and / or inductive heat source to heat a substrate material to form an aerosol. In various embodiments, the conductive heat source can include a heating assembly including a resistive heating element. The resistive heating element can be configured to generate heat when an electric current is induced therethrough. Conductive materials useful as resistive heating elements can be materials that have low mass, low density, and moderate resistivity, and are thermally stable at temperatures applied during use. Useful heating elements heat and cool rapidly, thus providing efficient use of energy. Rapid heating of the element can be beneficial in providing almost instantaneous volatilization of the aerosol-forming material in close proximity thereto. Rapid cooling prevents substantial volatilization (and thus waste) of the aerosol-forming material during periods when aerosol formation is not desired. Such heating elements may also allow for relatively precise control of the temperature range applied to the aerosol-forming material, especially when time-based current control is utilized. Useful conductive materials are typically chemically non-reactive with the materials being heated (e.g., aerosol-forming materials and other inhalable substance materials), so as not to adversely affect the flavor or content of the aerosol or vapor generated. Some exemplary, non-limiting materials that may be used as conductive materials include carbon, graphite, carbon / graphite composites, metals, ceramics, such as metal and non-metal carbides, nitrides, oxides, silicides, intermetallic compounds, cermets, metal alloys, and metal foils. In particular, refractory materials may be useful. Various, different materials may be mixed to achieve the desired properties of resistivity, mass, and thermal conductivity. In certain embodiments, metals that may 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 disclosed in U.S. Pat. Nos. 5,060,671 to Counts et al.; 5,093,894 to Deevi et al.; 5,224,498 to Deevi et al.; 5,228,460 to Sprinkel Jr. et al.; 5,322,075 to Deevi et al.; 5,353,813 to Deevi et al.; and 5,353,813 to Deevi et al., the disclosures of which are incorporated herein by reference in their entireties. No. 5,468,936 to Das; U.S. Patent No. 5,498,850 to Das; U.S. Patent No. 5,659,656 to Das; U.S. Patent No. 5,498,855 to Deevi et al.; U.S. Patent No. 5,530,225 to Hajaligol; U.S. Patent No. 5,665,262 to Hajaligol; U.S. Patent No. 5,573,692 to Das et al.; and U.S. Patent No. 5,591,368 to Fleischhauer et al.

[0207] In various embodiments, the heating member may be provided in various forms, such as a foil, foam, mesh, hollow ball, half ball, disk, spiral, fiber, wire, film, thread, strip, ribbon, or cylinder. Such heating members often include a metallic material and are configured to generate heat as a result of electrical resistance associated with passing an electric current therethrough. Such resistive heating members may be disposed in close proximity to and / or in direct contact with the substrate portion. For example, in one embodiment, the heating member may include a cylinder or other heating device located on the control device 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 member may also be coated with any of these or other conductive materials. The heating member may be located proximal to the engagement end of the control device 102 and configured to substantially surround a portion of the heated end 106 of the aerosol generation element 104, including the substrate portion 110. In this manner, the heating element can be located proximate to the substrate portion 110 of the aerosol generating element 104 when the aerosol generating element 104 is inserted into the control device 102. In other examples, at least a portion of the heating element can penetrate at least a portion of the aerosol generating element (e.g., one or more protrusions and / or spikes penetrating the aerosol generating element) when the aerosol generating element is inserted into the control device. Note that in some embodiments, the heating element can include a cylinder, while in other embodiments, the heating element can take various forms and in some embodiments, can directly contact and / or penetrate the substrate portion. In addition to being configured for use with a conductive heat source as described above, the aerosol generating elements disclosed herein may also be configured for use with an inductive heat source to heat the substrate portion to form an aerosol. In various embodiments, the inductive heat source can include a resonant transformer, which can include a resonant transmitter and a resonant receiver (e.g., a susceptor).In some embodiments, the resonant transmitter and the resonant receiver can be located in the control device 102. In other embodiments, the resonant receiver, or a portion thereof, can be located in the aerosol generation element 104. For example, in some embodiments, the control device 102 can include a resonant transmitter, which can include, for example, a foil material, a coil, a cylinder, or other structure configured to generate an oscillating magnetic field, and a resonant receiver, which can include one or more protrusions that extend to or are surrounded by a substrate portion. In some embodiments, the aerosol generation element is in intimate contact with the resonant receiver.

[0208] In other embodiments, the resonant transmitter can include a helical coil configured to surround the periphery of the cavity that receives the aerosol generating element, particularly the substrate portion of the aerosol generating element. In some embodiments, the helical coil can be located between the outer wall of the device and the receiving cavity. In one embodiment, the coil winding can have a circular cross-sectional shape. However, in other embodiments, the coil winding can have a variety of other cross-sectional shapes, including, but not limited to, an elliptical shape, a rectangular shape, an L-shape, a T-shape, a triangular shape, and combinations thereof. In another embodiment, the pin can extend into a portion of the receiving cavity, and the pin can include a coil structure, for example, around or within the pin, and thus include a resonant transmitter. In various embodiments, the aerosol generating element can be received in the receiving cavity, and one or more components of the aerosol generating element can function as a resonant receiver. In some embodiments, the aerosol generating element includes a resonant receiver. Other possible resonant transformer components, including resonant transmitters and resonant receivers, are described in U.S. Patent Application Publication No. 2019 / 0124979 by Sebastian et al., which is incorporated by reference in its entirety.

[0209] In various embodiments, the aerosol generation element 104 and the control device 102 may be permanently or separably aligned in a operative relationship. In this regard, Fig. 2 illustrates the aerosol delivery device 100 in a coupled configuration, whereas Fig. 2 illustrates the aerosol delivery device 100 in a decoupled configuration. The aerosol generation element 104 may be coupled with the control device 102 by various mechanisms to provide a threaded engagement, a press fit engagement, an interference fit, a sliding fit, a magnetic engagement, or the like.

[0210] In various embodiments, the aerosol delivery device 100 according to exemplary embodiments of the present disclosure can have various overall shapes, including, but not limited to, an overall shape that may be defined as a substantially rod-like or substantially tubular shape or a substantially cylindrical shape. In the embodiment of Figs. 2-3, the device 100 has a substantially circular cross-section. However, other cross-sectional shapes (e.g., oval, square, triangular, etc.) are also encompassed by the present disclosure. For example, in some embodiments, one or both of the controller 102 or the aerosol generation element 104 (and / or any subcomponents) can have a substantially rectangular shape, such as a substantially rectangular cuboid shape (e.g., a shape similar to a USB flash drive). In other embodiments, one or both of the controller 102 or the aerosol generation element 104 (and / or any subcomponents) can have other handheld shapes. For example, in some embodiments, the controller 102 can 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 device 102 and the aerosol generation element 104.

[0211] 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 proximate 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 close enough to the substrate portion so that heat from the heat source can volatilize the substrate portion (e.g., the aerosol-forming material therein) and 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 is noted that the foregoing terms are intended 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 inhalable substance 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 specified.

[0212] As mentioned above, the aerosol delivery device 100 of various embodiments can incorporate a battery and / or other power supply to provide a sufficient current flow to provide various functionalities to the aerosol delivery device, such as, for example, powering a heat source, powering a control system, powering an indicator, etc. As will be discussed in more detail below, the energy source can take various embodiments. The energy source can deliver sufficient power to rapidly activate the heat source to cause the formation of an aerosol and power the aerosol delivery device through use for a desired period of time. In some embodiments, the energy source is sized to fit conveniently within the aerosol delivery device so that the aerosol delivery device is easily handled. Examples of useful energy sources include lithium-ion batteries, which are typically rechargeable (e.g., rechargeable lithium-manganese dioxide batteries). In particular, lithium polymer batteries can be used, as they can provide a higher level of safety than such batteries. Other types of batteries, such as N50-AAACADNICA nickel-cadmium cells, can also be used. Furthermore, the exemplary energy source is lightweight enough that the desired smoking experience is not compromised. Some examples of possible energy 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., the disclosures of each of which are incorporated by reference in their entirety.

[0213] In certain embodiments, one or both of the control device 102 and the aerosol generation element 104 can be referred to as disposable or reusable. For example, the control device 102 can have a replaceable or rechargeable battery, a solid-state battery, a thin-film solid-state battery, a rechargeable supercapacitor, etc., and can thus be combined with any type of recharging technology, including connection to a wall charger, connection to a car charger (i.e., a cigarette lighter case), and connection to a computer, e.g., a connection to a solar cell (sometimes also called a solar cell) or solar panel solar cell via a Universal Serial Bus (USB) cable or connector (e.g., USB 2.0, 3.0, 3.1, USB Type C), a wireless charger, e.g., a charger using inductive wireless charging (e.g., including wireless charging according to the Wireless Power Consortium (WPC) Qi wireless charging standard), or a wireless radio frequency (RF)-based charger. An example of an inductive wireless charging system is described in U.S. Patent Application Publication No. 2017 / 0112196 by Sur et al., which is incorporated herein by reference in its entirety. Further, in some embodiments, the aerosol generating element 104 can include a single-use device. Single-use components for use in a control device are disclosed in U.S. Patent No. 8,910,639 to Chang et al., which is incorporated herein by reference in its entirety.

[0214] In further embodiments, the energy source may also include a capacitor. The capacitor may be capable of discharging faster than a battery, and may be charged during a puff, allowing the battery to discharge into the capacitor at a slower rate than if it were used to directly power a heat source. For example, a supercapacitor, such as an electric double-layer capacitor (EDLC), may be used separately from or in combination with a battery. When used alone, the supercapacitor may be recharged before each use of the article. Thus, the device may also include a charger component that may be attached to the smoking article between each use to replenish the supercapacitor.

[0215] Additional components can be utilized in the aerosol delivery device of the present disclosure. For example, the aerosol delivery device can include a flow sensor that is sensitive to either a change in pressure or a change in airflow when a consumer draws on the article (e.g., a puff-activated switch). Other possible current activation / deactivation mechanisms can include a temperature-activated on / off switch or a lip pressure-activated switch. An exemplary mechanism that can provide such puff-activated capability includes a model 163PC01D36 silicon sensor, manufactured by MicroSwitch division of Honeywell, Inc., Freeport, Ill. Representative flow sensors, current regulators and other current control elements, 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. See also 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.

[0216] In another example, the aerosol delivery device can include a first conductive surface configured to contact a first body part of a user holding the device and a second conductive surface conductively separated from the first conductive surface and configured to contact a second body part of the user. Thus, when the aerosol delivery device detects a change in conductivity between the first conductive surface and the second conductive surface, the vaporizer is activated to vaporize the substance so that the vapor can be inhaled by the user-held unit. The first body part and the second body part can be the lips or the hand. The two conductive surfaces can also be used to charge a battery contained within the personal vaporizer unit. The two conductive surfaces can also form a connector or part of a connector that can be used to output data stored in the memory. See U.S. Pat. No. 9,861,773 to Terry et al., which is incorporated herein by reference in its entirety.

[0217] 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 may be associated with the mouth end of the device that detects the user's lip activity associated with taking a puff and then triggers heating of the heating device. U.S. Patent No. 5,372,148 to McCafferty et al. discloses a puff sensor for controlling the flow of energy to a heat load array in response to a pressure drop through a 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 the infrared transmittance of an inserted component and a controller that executes a detection routine when a component is inserted into the receptacle. U.S. Patent No. 6,040,560 to Fleischhauer et al. describes a defined executable power cycle with multiple differential phases. U.S. Patent No. 5,934,289 to Watkins et al. discloses a photonic optronic component. U.S. Patent No. 5,954,979 to Counts et al. discloses a means for modifying the resistance to draw through a smoking device. U.S. Patent No. 6,803,545 to Blake et al. discloses a particular battery configuration for use in a smoking device. U.S. Patent No. 7,293,565 to Griffen et al. discloses various charging systems for use with smoking devices. U.S. Patent No. 8,402,976 to Fernando et al. discloses computer interface means for a smoking device that facilitates charging and allows computer control of the device. U.S. Patent No. 8,689,804 to Fernando et al. discloses an identification system for a smoking device. PCT Patent Application Publication WO 2010 / 003480 to Flick discloses a fluid flow sensing system that indicates puffs in an aerosol generating system. All of the foregoing disclosures are incorporated herein by reference in their entirety.

[0218] Further examples of components related to electronic aerosol delivery articles and disclosed materials or components that can be used in the devices of the present invention 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; and U.S. Pat. No. 7,8 No. 96,006; U.S. Patent No. 6,772,756 to Shayan; U.S. Patent Nos. 8,156,944 and 8,375,957 to Hon; 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. 9,225,555 to DePiano et al. 0,302; Hon, U.S. Patent Application Publication Nos. 2006 / 0196518 and 2009 / 0188490; Oglesby et al., U.S. Patent Application Publication No. 2010 / 0024834; Wang, U.S. Patent Application Publication No. 2010 / 0307518; Hon, PCT Patent Application Publication No. WO2010 / 091593; and Foo, PCT Patent Application Publication No. WO2013 / 089551. In addition, Worm et al., U.S. Patent Application Publication No. 2017 / 0099877, discloses capsules that may be included in aerosol delivery devices and fob configurations for aerosol delivery devices, and is incorporated herein by reference in its entirety. Various materials disclosed by the aforementioned documents may be incorporated into the device of the present invention in various embodiments, and all of the aforementioned disclosures are incorporated herein by reference in their entirety.

[0219] 3, in the illustrated embodiment, the aerosol generating element 104 includes a heated end 106 (configured to be inserted into the control device 102) and a mouth end 108 (where a user draws on to create an aerosol). At least a portion of the heated end 106 includes a substrate portion 110. In some embodiments, the substrate portion 110 includes a substrate including an aerosol-forming material, each as disclosed herein. In various embodiments, the aerosol generating element 104, or a portion thereof, may be packaged in an outer overwrap material 112. In various embodiments, the mouth end 108 of the aerosol generating element 104 may include a filter 114, which may be made of, for example, a cellulose acetate or polypropylene material. The filter 114 may also or instead contain 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. In various embodiments, the filter 114 can increase the structural integrity of the mouth end of the aerosol generation element 104 and / or provide filtering capabilities, if desired, and / or provide resistance to draw. In some embodiments, the filter can include separate segments. For example, some embodiments can include a segment that provides filtering, a segment that provides resistance to draw, a hollow segment that provides space for cooling the aerosol, a segment that provides greater structural integrity, other filter segments, and any one or any combination of the above.

[0220] In some embodiments, the material of the outer overwrap 112 can include a material that resists heat transfer, which can include paper or other fibrous materials, such as cellulosic materials. The outer overwrap material can also include at least one filler material embedded or dispersed within the fibrous material. In various embodiments, the filler material can have the form of water-insoluble particles. Additionally, the filler material can incorporate inorganic components. In various embodiments, the outer overwrap can be formed of multiple layers, such as an underlying, bulk layer, and a top layer, such as a typical cigarette wrapper paper. Such materials can include, for example, lightweight "rag fibers," such as flax, hemp, sisal, rice straw, and / or esparto. The outer overwrap can also include materials commonly used in filter elements of conventional cigarettes, such as cellulose acetate. Additionally, the excess length of the outer overwrap at the mouth end 108 of the aerosol generating element can function simply to separate the substrate portion 110 from the consumer's mouth, or to provide space for positioning of a filter material as described below, or to affect inhalation of the article, or to affect the flow characteristics of the vapor or aerosol escaping from the device during inhalation. Further discussion regarding configurations for outer overwrap materials that can be used in the present disclosure can be found in U.S. Patent No. 9,078,473 to Worm et al., which is incorporated herein by reference in its entirety.

[0221] In some embodiments, the aerosol generating element and the control device may be provided together as a generally complete aerosol delivery article, although the components may be provided separately. For example, the present disclosure also encompasses disposable units for use with reusable smoking articles or reusable pharmaceutical delivery articles. In certain embodiments, such disposable units (which may be aerosol generating elements as illustrated in the attached figures) may include a substantially tubular shaped body having a heated end configured to engage with a reusable aerosol delivery article, opposing mouth ends configured to allow delivery of a substance for inhalation to a consumer, and a wall having an outer surface and an inner surface that defines an interior space. Various embodiments of aerosol generating elements (or cartridges) are described in U.S. Patent No. 9,078,473 by Worm et al., which is incorporated herein by reference in its entirety.

[0222] Although some figures described herein depict the controller and the aerosol generation element in operative relationship, it is understood that the controller and the aerosol generation element can exist as separate devices, and therefore any discussion provided elsewhere herein relating to combined components should also be understood to apply to the controller and the aerosol generation element as individual and separate components.

[0223] In another aspect, the present disclosure may be directed to a kit providing various components described herein. For example, the kit may include a control device having one or more aerosol generating elements. The kit may further include a control device having one or more charging components. The kit may further include a control device having one or more batteries. The kit may further include a control device having one or more aerosol generating elements and one or more charging components and / or one or more batteries. In further embodiments, the kit may include multiple aerosol generating elements. The kit may further include multiple aerosol generating elements and one or more batteries and / or one or more charging components. In the above embodiments, the aerosol generating elements or the control device may include a heating element therein. The kit of the present invention may further include a case (or other packaging, shipping or storage component) for housing 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.

[0224] 4 illustrates a schematic perspective view of an aerosol generating element according to an exemplary embodiment of the present disclosure. In particular, FIG. 4 illustrates an aerosol generating element 104 having a substrate portion 110 that includes a series of overlapping layers 130 of a substrate 120 in sheet form. With reference to the above description, in the illustrated embodiment, the substrate sheet 120 includes a film or layer disclosed herein. In various embodiments, the term "overlapping layers" can also include bundled, rolled, crimped, and / or otherwise assembled layers where individual layers may not be apparent.

[0225] For example, Figure 5 illustrates a schematic cross-sectional view of a substrate portion 110 of an aerosol generating element 104 according to an exemplary embodiment of the present disclosure. In particular, Figure 5 illustrates the substrate portion 110, which includes a series of overlapping layers 130 of a substrate sheet 120. In the embodiment shown, 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 first cover layer 132 can be constructed via a casting process, such as the method described in U.S. Patent No. 5,697,385 to Seymour et al., the disclosure of which is incorporated herein by reference in its entirety.

[0226] In the illustrated embodiment, at least a portion of the overlapping layer 130 and the first cover layer 132 are substantially surrounded about their outer surfaces by the second cover layer 134. The composition of the second cover layer 134 may vary, but in the illustrated embodiment, the second cover layer 134 comprises a metal foil material, e.g., an aluminum foil material. In other embodiments, the second cover layer may comprise other materials, including, but not limited to, copper materials, tin materials, gold materials, alloy materials, ceramic materials, or other thermally conductive amorphous carbon-based materials and / or any combination thereof. The illustrated embodiment further comprises a third cover layer 136, which is substantially surrounded about its outer surfaces by the overlapping layer 130, the first cover layer 132, and the second cover layer 134. In the illustrated embodiment, the third cover layer 136 comprises a paper material, e.g., a conventional cigarette paper. In various embodiments, the paper material can include rag fibers, for example non-wood plant fibers, and can include flax, hemp, sisal, rice straw, and / or esparto fibers.

[0227] In various embodiments, other components may be present between the substrate portion 110 and the mouth end 108 of the aerosol generating element 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 element 104: an air gap; a hollow tube structure; a phase change material for cooling air; a flavor release medium; an ion exchange fiber 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.

[0228] Fig. 6 illustrates a perspective view of an aerosol generating element according to another exemplary embodiment of the present disclosure, and Fig. 7 illustrates a perspective view of the aerosol generating element of Fig. 5 with the outer packaging removed. In particular, Fig. 6 illustrates the aerosol generating element 200 including the outer packaging 202, and Fig. 7 illustrates the aerosol generating element 200 with the outer packaging 202 removed to reveal other components of the aerosol generating element 200. In the illustrated embodiment, the aerosol generating element 200 of the illustrated embodiment includes a heat source 204, a substrate portion 210, an intermediate component 208, and a filter 212. In the illustrated embodiment, the intermediate component 208 and the filter 212 together include a mouthpiece 214.

[0229] In various embodiments, the heat source 204 may be configured to generate heat upon ignition thereof. In the illustrated embodiment, the heat source 204 has a generally cylindrical shape and includes a combustible fuel element incorporating a combustible carbonaceous material. In other embodiments, the heat source 204 may have different shapes, for example, a prismatic shape having a triangular, cubic, or hexagonal cross section. Carbonaceous materials generally have a high carbon content. Certain exemplary carbonaceous materials may be composed primarily of carbon and / or may have a carbon content, typically greater than about 60 percent, typically greater than about 70 percent, often greater than about 80 percent, and frequently greater than about 90 percent, on a dry weight basis.

[0230] In some cases, the heat source 204 can incorporate elements other than combustible carbonaceous material (e.g., tobacco components, such as powdered tobacco or tobacco extracts, as described herein above; 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 for reducing the temperature of the heat source). While the specific dimensions of applicable heat sources may vary, in some embodiments, the heat source 204 can have a length in the range of approximately 7 mm to approximately 20 mm, inclusive, and in some embodiments, approximately 17 mm, and an overall diameter in the range of approximately 3 mm to approximately 8 mm, inclusive, and in some embodiments, approximately 4.8 mm (and in some embodiments, approximately 7 mm). In other embodiments, the heat source can be constructed in a variety of ways, but in the embodiment shown, the heat source 204 is extruded or mixed using crushed or powdered carbonaceous material, with a dry weight basis of approximately 0.5 g / cm 3 Larger, often around 0.7 g / cm 3 Larger, often around 1g / cm 3It has a greater density. See, for example, the types of fuel source components, formulations, and configurations 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 entirety. 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 includes an extruded monolithic carbonaceous material having a generally cylindrical shape, with a plurality of grooves 216 extending longitudinally from a first end of the extruded monolithic carbonaceous material to an opposing second end of the extruded monolithic carbonaceous material. In some embodiments, the aerosol delivery device, particularly the heat source, can include a heat transfer element. In various embodiments, the heat transfer element can be proximate to the heat source, and in some embodiments, the heat transfer element can be located within or within the heat source. Some examples of heat transfer elements are described in U.S. Patent Application Publication No. 2019 / 0281891 by Hejazi et al., which is incorporated by reference in its entirety.

[0231] 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 as few as two grooves and still other embodiments may include as few as a single groove. Still other embodiments may not include any grooves at all. Additional embodiments may include multiple grooves that may be of unequal width and / or depth and may be unequally 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 of the extruded monolithic carbonaceous material to its opposing second end. In some embodiments, the heat source may include a foamed carbon monolith formed in 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 reduction in the time spent igniting the heat source. In some other embodiments, the heat source may be co-extruded with a layer of insulation (not shown), thereby reducing manufacturing time and costs.Other embodiments of the fuel element include carbon fiber or other heat source embodiments of the type described in U.S. Patent No. 4,922,901 to Brooks et al., such as those disclosed in U.S. Patent Application Publication No. 2009 / 0044818 to Takeuchi et al., each of which is incorporated herein by reference in its entirety.

[0232] Typically, the heat source is positioned sufficiently close to the substrate portion having one or more aerosol-forming materials such that an aerosol formed / volatilized by application of heat from the heat source to the aerosol-forming materials (as well as any flavorings, medicines, and / or the like similarly provided for delivery to the user) is 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 is noted that the foregoing terms are intended 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 inhalable substance is released in the form of a vapor or an aerosol or a mixture thereof.

[0233] 6 and 7, the outer packaging 202 can 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 together. In various embodiments, the outer packaging 202 is configured to be held in the wrapped position in any manner, including via adhesive or fasteners, etc., allowing the outer packaging 202 to remain in the wrapped position. Alternatively, in some other aspects, the outer packaging 202 can be configured to be removable, if desired. For example, the outer packaging 202 can be removed from the heat source 204, the substrate portion 210, and / or the mouthpiece 214 while the outer packaging 202 remains in the wrapped position.

[0234] In some embodiments, in addition to the outer wrapping 202, the aerosol delivery device can also include a liner configured to surround at least a portion of the substrate portion 210 and the heat source 204. In other embodiments, the liner can surround only a portion of the length of the substrate portion 210, while in some embodiments, the liner can substantially surround the entire length of the substrate portion 210. In some embodiments, the outer wrapping 202 can include a liner. Thus, in some embodiments, the outer wrapping 202 and the liner can be separate materials provided together (e.g., bonded, condensed, or otherwise joined together as a laminate). In other embodiments, the outer wrapping 202 and the liner can be the same material. In either case, the liner can be configured to thermally regulate the heat generated by the ignited heat source 204 to be conducted radially outward from the liner. Thus, in some embodiments, the liner can be constructed of a metal foil material, an alloy material, a ceramic material, or other thermally conductive amorphous carbon-based material and / or aluminum material, and in some embodiments, can include a laminate. In some embodiments, depending on the material of the outer packaging 202 and / or the liner, a thin layer of insulating material may be provided radially outward from the liner. Thus, the liner may in some aspects advantageously provide a way to engage two or more separate components of the aerosol generating element 200 (e.g., the heat source 204, the substrate portion 210, and / or a portion of the mouthpiece 214), while also promoting heat transfer axially therealong, but limiting heat conduction radially outward.

[0235] As shown in FIG. 6 , the outer wrapping material 202 (and, optionally, the liner and substrate portion 210) may also include one or more openings formed therethrough that allow for the ingress of air when drawing on the mouthpiece 214. In various embodiments, the size and number of these openings may vary based on the requirements of a particular configuration. In the embodiment shown, the multiple openings 220 are located proximate the end of the substrate portion 210 closest to the heat source 204, and multiple separate cooling openings 221 are formed in the outer wrapping material 202 (and, in some embodiments, the liner) in an area proximal to the filter 212 of the mouthpiece 214. While other embodiments may vary, in the embodiment shown, the openings 220 include multiple openings substantially uniformly arranged around the outer surface of the aerosol generating element 200, and the openings 221 also include multiple openings substantially uniformly arranged around the outer surface of the aerosol generating element 200. In various embodiments, the multiple openings can be formed in various manners through the outer packaging material 202 (and, in some embodiments, the liner), but in the embodiment shown, the multiple openings 220 and the multiple separate cooling openings 221 are formed via laser drilling.

[0236] Referring again to FIG. 7 , the aerosol generating element 200 in the illustrated implementation also includes an intermediate component 208 and at least one filter 212. Note that in various implementations, the intermediate component 208 or the filter 212, individually or together, may be considered the mouthpiece 214 of the aerosol generating element 200. While in various implementations, neither an intermediate component nor a filter need be included, in the illustrated implementation, the intermediate component 208 includes a substantially rigid member that is substantially inflexible along its longitudinal axis. In the illustrated implementation, the intermediate component 208 includes a hollow tubular structure and is included to add structural integrity to the aerosol generating element 200 and to provide cooling of the generated aerosol. In some implementations, the intermediate component 208 can be used as a container to collect the aerosol. In various implementations, 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 implementation shown, the intermediate component 208 includes a hollow cylindrical element constructed of paper or plastic material (e.g., ethyl vinyl 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 wrapped rod or cylindrical disk constructed of a gas permeable material (e.g., cellulose acetate or fibers such as paper or rayon, or polyester fibers).

[0237] As described, in some implementations, the mouthpiece 214 can include a filter 212 configured to receive aerosol therethrough in response to a draw applied to the mouthpiece 214. In various implementations, the filter 212 is provided as a circular disk, in some embodiments, radially and / or longitudinally disposed proximal to the second end of the intermediate component 208. In this manner, upon drawing on the mouthpiece 214, the filter 212 receives the aerosol flowing through the intermediate component 208 of the aerosol generating element 200. In some implementations, the filter 212 can include separate segments. For example, some implementations can include a segment that provides filtering, a segment that provides a resistance to draw, a hollow segment that provides space to cool the aerosol, a segment that provides higher structural integrity, other filter segments, and any one or any combination of the above. In some implementations, the filter 212 can also or instead contain 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.

[0238] In various implementations, the size and shape of intermediate component 208 and / or filter 212 may vary, for example, the length of intermediate component 208 may range from about 10 mm to about 30 mm (inclusive), the diameter of intermediate component 208 may range from about 3 mm to about 8 mm (inclusive), the length of filter 212 may range from about 10 mm to about 20 mm (inclusive), and the diameter of filter 212 may range from about 3 mm to about 8 mm (inclusive). In the implementation shown, intermediate component 208 has a length of about 20 mm and a diameter of about 4.8 mm (and in some implementations, about 7 mm), and filter 212 has a length of about 15 mm and a diameter of about 4.8 mm (or in some implementations, about 7 mm).

[0239] In various implementations, ignition of the heat source 204 results in aerosolization of the aerosol-forming material associated with the substrate portion 210. In certain embodiments, the components of the substrate portion 210 do not undergo thermal decomposition (e.g., charring, scorching, or burning) to any significant extent, and the aerosolized components are entrained in air drawn through the aerosol generating element 200, including the filter 212, to the user's mouth. In various implementations, the mouthpiece 214 (e.g., the intermediate component 208 and / or the filter 212) is configured to receive the generated aerosol therethrough in response to a draw applied by a user to the mouthpiece 214. In some implementations, the mouthpiece 214 may be fixedly engaged to the substrate portion 210. For example, adhesives, bonding, 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 to the end of the substrate portion 210.

[0240] Although the aerosol delivery device and / or aerosol generating element according to the present disclosure may take various embodiments as discussed in detail above, the use of the aerosol delivery device and / or aerosol generating element by a consumer falls within the same scope. The above description of the use of the aerosol delivery device and / or aerosol generating element is applicable to the various embodiments described through minor modifications, which will be apparent to those skilled in the art in view 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, and is provided to comply with all necessary requirements of the disclosure herein.

[0241] Many modifications and other embodiments of the present disclosure will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. It is to be understood, therefore, that the disclosure is not limited to the specific embodiments disclosed herein, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms have been employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. EXAMPLES

[0242] Aspects of the present invention will be more fully illustrated by the following examples, which are presented to illustrate certain specific aspects of the invention and are not to be construed as limiting thereof.

[0243] Example 1. Cast sheet substrate containing microcrystalline cellulose Examples of cast sheet substrate embodiments of the present disclosure were prepared according to the formulas provided in Table 1. The actual ingredients and percentages may vary depending on the desired properties of the final product.

[0244] Water and carboxymethyl cellulose binder were mixed in a high shear mixer (e.g., kitchen blender) in sufficient amounts to produce a 2-3% by weight binder solution. The mixer was charged with water and set at low to medium speed. Carboxymethyl cellulose was added and the suspension was mixed until complete dispersion or dissolution occurred. The mixing speed was increased and mixing continued for an additional 10-15 minutes. Wood pulp was added and mixing continued at high speed for another 5 minutes. The speed was reduced and the microcrystalline cellulose was slowly added. Mixing continued for approximately 5-6 minutes until all the microcrystalline cellulose was dispersed. Glycerol was added and mixing continued at medium speed for another 5 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 an opening gap of 2-5 mm. The cast material or film was then dried into a flat sheet form by conveying the film through a 200 foot convection tunnel dryer containing multiple heating zones (e.g., in the range of 80-150°C). The sheet was dried to about 8-10% moisture. The flat sheet former was separated from the belt, wound onto a bobbin, and vacuum sealed in a polyethylene bag to prevent moisture pick-up and ingress during shipping. The bobbin was then unwound and the sheet was cut into strips (e.g., about 25-20 cuts per square inch).

[0245] [Table 1]

[0246] Example 2. Cast sheet substrate containing microcrystalline cellulose In another embodiment, a cast sheet substrate was prepared using the procedure of Example 1, but using a larger range of weight percents of microcrystalline cellulose, comprising the ingredients set forth in Table 2 below. The actual ingredients and percentages may vary depending on the desired properties of the final product.

[0247] [Table 2]

[0248] Example 3. Cast sheet substrate with microcrystalline cellulose-alginate binder In one embodiment, a cast sheet substrate was prepared using the procedure of Example 1, except that sodium alginate was used instead of carboxymethylcellulose, containing the ingredients set forth in Table 3 below. The actual ingredients and percentages may vary depending on the desired properties of the final product.

[0249] [Table 3]

[0250] result The measured densities and filler capacities for the formulations prepared according to Examples 1-3 are provided in Table 4. In general, sheet density was reduced with the alginate binder, and shredding (22 cuts per inch) increased the filler capacity.

[0251] [Table 4]

Claims

1. A substrate for use in an aerosol delivery device, comprising: microcrystalline cellulose; one or more binders; and an aerosol forming material The substrate.

2. The substrate according to claim 1, wherein the microcrystalline cellulose is present in an amount of 25% by weight or more based on the total dry weight of the substrate.

3. The substrate according to claim 1, wherein the microcrystalline cellulose is present in an amount of 30% by weight or more based on the total dry weight of the substrate.

4. The substrate according to claim 1, wherein the microcrystalline cellulose is present in an amount in the range of 25% to 60% by weight, 30% to 55% by weight or 35% to 50% by weight based on the total dry weight of the substrate.

5. The substrate according to claim 1, further comprising wood pulp in an amount of 5% to 15% by weight based on the total dry weight of the substrate.

6. The substrate according to claim 1, wherein the binder is selected from the group consisting of cellulose ethers, alginates, starches and combinations thereof.

7. The substrate according to claim 1, wherein the binder is a cellulose ether selected from the group consisting of methylcellulose, hydroxypropylcellulose, hydroxypropylmethylcellulose, hydroxyethylcellulose, carboxymethylcellulose and combinations thereof.

8. The substrate according to claim 1, wherein the binder is carboxymethylcellulose.

9. The substrate according to claim 1, wherein the binder is an alginate.

10. The substrate according to claim 1, wherein the aerosol forming material is present in an amount of 10% by weight or more based on the total dry weight of the substrate.

11. The substrate according to claim 1, wherein the aerosol forming material is present in an amount of 20% by weight or more based on the total dry weight of the substrate.

12. The substrate according to claim 1, wherein the aerosol forming material is present in an amount in the range of 10% to 70% by weight.

13. The substrate according to claim 1, wherein the aerosol forming material is present in an amount in the range of 30% to 60% by weight.

14. The substrate according to claim 1, wherein the aerosol forming material is selected from the group consisting of water, polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, non-fatty acid esters, waxes, cannabinoids, terpenes, sugar alcohols and combinations thereof.

15. The substrate according to claim 1, wherein the aerosol forming material is a polyhydric alcohol.

16. The substrate according to claim 14, wherein the polyhydric alcohol is selected from the group consisting of glycerol, propylene glycol, 1,3 - propanediol, diethylene glycol, triethylene glycol, and combinations thereof.

17. The substrate according to claim 1, further comprising a perfume, an active ingredient, or a combination thereof.

18. The substrate according to claim 17, wherein the active ingredient comprises a nicotine component.

19. 30 to 50% by weight of microcrystalline cellulose; 5 to 10% by weight of wood pulp; 5 to 10% by weight of a binder; and 30 to 60% by weight of an aerosol - forming material The substrate according to claim 1, comprising.

20. The substrate according to claim 19, wherein the binder is carboxymethyl cellulose or sodium alginate.

21. The substrate according to claim 20, wherein the aerosol - forming material is glycerol.

22. The substrate according to claim 1, which is in the form of a sheet.

23. The substrate according to claim 1, substantially free of tobacco material.

24. The substrate according to claim 1, substantially free of nicotine.

25. An aerosol - generating element for use with an aerosol delivery device, the aerosol - generating element comprising a substrate according to any one of claims 1 to 24.

26. The aerosol - generating element according to claim 25, further comprising an aerosol - forming material, and the aerosol - forming material comprises a tobacco material.

27. The aerosol - generating element according to claim 25, further comprising a support, and the substrate is attached to the support.

28. The aerosol - generating element according to claim 27, wherein the support is flat.

29. The aerosol - generating element according to claim 25, wherein the substrate is blended with a tobacco material.

30. The aerosol - generating element according to claim 26, wherein the tobacco material exists as a plurality of strips.

31. The aerosol - generating element according to claim 25, comprising a plurality of strips of substrate.

32. The aerosol - generating element according to claim 25, comprising a plurality of layers of substrate.

33. The aerosol - generating element according to claim 25, a heat source configured to heat the aerosol - generating element to form an aerosol, and an aerosol path extending from the aerosol - generating element and extending along a length configured to carry the aerosol to the mouthpiece of the aerosol delivery device An aerosol delivery device comprising.

34. The aerosol delivery device according to claim 33, wherein the heat source includes either an electric heating element or a combustible ignition source.

35. The aerosol delivery device according to claim 33, wherein the heat source is a combustible ignition source including a carbon-based material.

36. The aerosol delivery device according to claim 33, wherein the heat source is an electric heating element.

37. The aerosol delivery device according to claim 36, further comprising an energy source electronically connected to the heating element.

38. The aerosol delivery device according to claim 37, further comprising a controller configured to control the power transmitted to the heating element by the energy source.

39. The aerosol delivery device according to claim 33, wherein the heat source is a conductive heat source or an inductive heat source.

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