Substrate materials, including beads, for aerosol delivery devices

Abstract

The present disclosure provides a composite substrate configured for use with an aerosol-generating component for an aerosol delivery device. The composite substrate comprises a first substrate material and a second substrate material attached thereto. The first substrate material comprises a first filler material, a first binder, and a first aerosol-forming material, and the second substrate material comprises a second filler material and a second binder. Methods for making the composite substrate and the aerosol-generating component, as well as an aerosol delivery device comprising the composite substrate, are further provided. Such a device utilizes an electrical heating or combustible ignition source to heat the composite substrate, resulting in an aerosol form of the inhalable substance.

Description

[Technical field]

[0001] The present disclosure relates to aerosol generating components, aerosol delivery devices and aerosol delivery systems, such as smoking articles and components that provide inhalable substances in aerosol form for human consumption, generally without significant combustion, by utilizing electrical heating or combustible ignition sources to heat aerosol-forming materials. [Background technology]

[0002] Many smoking articles have been proposed over the years as an improvement or alternative to smoking products based on the combustion of tobacco for use. Some exemplary alternatives include devices in which a solid or liquid fuel is burned to transfer heat to the tobacco or devices in which 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 smoking articles 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.; 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 produce 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 inhalable substances, insufficient loading of the aerosol-forming material onto the substrate, or poor sensory properties. [Means for solving the problem]

[0006] (Brief summary) The present disclosure relates to composite substrates configured for use in aerosol delivery devices that provide inhalable substances in aerosol form for human consumption by utilizing an electrical heat or combustible ignition source to heat the substrate.

[0007] Thus, in one aspect, the present disclosure provides a composite substrate configured for use in an aerosol delivery device, the composite substrate comprising: a first substrate material comprising a first filler material, a binder, and an aerosol-forming material; and a second substrate material affixed to the first substrate material, the second substrate material comprising a second filler material, a second binder, and a second aerosol-forming material.

[0008] In some embodiments, the second substrate material is in the form of one or more beads, spheres, or rods that are attached to or embedded within the first substrate material, hi some embodiments, the second substrate material is in the form of one or more beads.

[0009] In some embodiments, the first substrate material is in the form of a sheet. In some embodiments, the first substrate material is in the form of a strip or particulate material. In some embodiments, both the first substrate material and the second substrate material are in the form of sheets attached together in a layered configuration.

[0010] In some embodiments, the first and second substrate materials have one or more of different compositions, different densities, and different outer shapes. In some embodiments, the densities of the first and second substrate materials differ by at least about 10%, e.g., about 10%, about 15%, or about 20%. In some embodiments, the density of the second substrate material is at least about 10% higher than the density of the first substrate material, e.g., about 10%, about 15%, or about 20% higher.

[0011] In some embodiments, the first substrate material comprises at least about 50% by weight of the first filler, based on the total dry weight of the first substrate material, hi some embodiments, the first substrate material comprises from about 50% to about 75% by weight of the first filler, based on the total dry weight of the first substrate material.

[0012] In some embodiments, the first filler and the second filler are independently selected from the group consisting of tobacco materials, plant materials, wood pulp, natural or modified starch, maltodextrin, glucose, calcium carbonate, sugar alcohols, microcrystalline cellulose, and combinations thereof. In some embodiments, the first filler and the second filler are independently selected from the group consisting of tobacco materials, wood pulp, maltodextrin, calcium carbonate, and combinations thereof. In some embodiments, the first filler and the second filler are independently selected from the group consisting of wood pulp, maltodextrin, calcium carbonate, and combinations thereof.

[0013] In some embodiments, the first binder and the second binder comprise a cellulose ether independently selected from the group consisting of methyl cellulose, hydroxypropyl cellulose (HPC), hydroxypropyl methyl cellulose (HPMC), hydroxyethyl cellulose, carboxymethyl cellulose (CMC), and combinations thereof. In some embodiments, the first binder and the second binder comprise CMC.

[0014] In some embodiments, the first aerosol-forming material and the second aerosol-forming material are independently selected from the group consisting of water, polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, cannabinoids, terpenes, sugar alcohols, and combinations thereof. In some embodiments, the first aerosol-forming material and the second aerosol-forming material each comprise a polyhydric alcohol. In some embodiments, the polyhydric alcohol is selected from the group consisting of glycerin, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, triacetin, and combinations thereof.

[0015] In some embodiments, the first substrate material comprises the following: tobacco material in an amount of about 0% to about 70% by weight, based on the total wet weight of the first substrate material; wood pulp in an amount of about 0% to about 10% by weight, based on the total wet weight of the first substrate material; calcium carbonate in an amount of about 0% to about 30% by weight, based on the total wet weight of the first substrate material; maltodextrin in an amount of about 0% to about 40% by weight, based on the total wet weight of the first substrate material; glycerin in an amount of about 10% to about 20% by weight, based on the total wet weight of the first substrate material; carboxymethylcellulose in an amount of about 5% to about 15% by weight, based on the total wet weight of the first substrate material; and water in an amount up to about 30% by weight, based on the total wet weight of the first substrate material.

[0016] In some embodiments, the first substrate material further comprises a flavoring agent, an active ingredient, a tobacco extract, or a combination thereof, hi some embodiments, the active ingredient comprises a nicotine component.

[0017] In some embodiments, the bead, sphere, or rod comprises at least about 50% by weight of the second filler, based on the total dry weight of the bead, hi some embodiments, the bead, sphere, or rod comprises from about 50% to about 65% by weight of the second filler, based on the total dry weight of the bead.

[0018] In some embodiments, the second filler comprises tobacco material, plant material, calcium carbonate, or combinations thereof. In some embodiments, the second filler is selected from the group consisting of tobacco material, calcium carbonate, and combinations thereof.

[0019] In some embodiments, the second binder is selected from the group consisting of methylcellulose, hydroxypropylcellulose (HPC), hydroxypropylmethylcellulose (HPMC), hydroxyethylcellulose, carboxymethylcellulose (CMC), and combinations thereof. In some embodiments, the second binder is CMC.

[0020] In some embodiments, the beads, spheres, or rods comprise the following: tobacco material in an amount of about 20% to about 40% by weight, based on the total dry weight of the bead, sphere, or rod; calcium carbonate in an amount of about 20% to about 40% by weight, based on the total dry weight of the bead, sphere, or rod; glycerin in an amount of about 0% to about 20% by weight, based on the total dry weight of the bead, sphere, or rod; and carboxymethylcellulose in an amount of about 0% to about 2% by weight, based on the total dry weight of the bead, sphere, or rod.

[0021] In some embodiments, the beads, spheres or rods further comprise a flavoring agent, an active ingredient, or a combination thereof.

[0022] In some embodiments, the second aerosol forming material is selected from the group consisting of water, polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, cannabinoids, terpenes, sugar alcohols, and any combination thereof. In some embodiments, the polyhydric alcohol is selected from the group consisting of glycerol, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, triacetin, and combinations thereof.

[0023] In some embodiments, the composite substrate comprises about 10% to about 50% by weight of the beads, spheres, or rods, based on the total weight of the composite substrate.

[0024] In some embodiments, the beads, spheres or rods have a diameter ranging from about 0.1 mm to about 5 mm.

[0025] In some embodiments, the beads, spheres or rods are adhered to the surface of the first substrate material in a randomly arranged pattern.

[0026] In some embodiments, the beads, spheres or rods are adhered to the surface of the first substrate material in a uniformly spaced pattern.

[0027] In some embodiments, the substrate is substantially free of wood fibers, hi some embodiments, the substrate is substantially free of tobacco material.

[0028] In some embodiments, the composite substrate is in flat sheet form, gathered sheet form, multi-layer sheet form, rolled sheet form, or strip form. In some embodiments, the composite substrate is in strip form, with tobacco material further blended therein.

[0029] In another aspect, a method of making a composite substrate configured for use in an aerosol delivery device includes the steps of: (a) preparing a slurry comprising a first filler material, a first binder, and a first aerosol-forming material; (b) casting the slurry onto a support device to form a first substrate material in the form of a wet sheet; (c) preparing a second substrate material comprising a second filler material, a second binder, and a second aerosol-forming material, the second substrate material being in the form of beads, rods, or spheres; (d) depositing a second substrate material onto a surface of the first substrate material; and (e) drying the first substrate material onto which the second substrate material in bead-like form has been deposited to form a composite substrate, wherein the second substrate material in bead-like, rod-like or sphere-like form is adhered to a surface of the first substrate material. A method is provided that includes:

[0030] In some embodiments, the slurry comprises: tobacco or plant material in an amount of about 0% to about 70% by weight, based on the total wet weight of the slurry; wood pulp in an amount of about 0% to about 10% by weight, based on the total wet weight of the slurry, an additional first filler in an amount of about 0% to about 70% by weight, based on the total wet weight of the slurry, the additional first filler comprising natural or modified starch, maltodextrin, glucose, calcium carbonate, sugar alcohol, microcrystalline cellulose, or combinations thereof, based on the total wet weight of the slurry; a first aerosol forming material in an amount of about 10% to about 20% by weight, based on the total wet weight of the slurry; a cellulose ether in an amount of about 5% to about 15% by weight, based on the total wet weight of the slurry; and water in an amount up to about 30% by weight, based on the total wet weight of the slurry.

[0031] In some embodiments, the second substrate material in beaded, rod, or sphere form comprises: tobacco or plant material in an amount of about 20% to about 40% by weight, based on the total dry weight of the second substrate material; an additional second filler in an amount of about 20% to about 40% by weight, based on the total dry weight of the second substrate material; a second aerosol forming agent in an amount of about 0% to about 20% by weight, based on the total dry weight of the second substrate material; and a cellulose ether in an amount of about 0% to about 2% by weight, based on the total dry weight of the second substrate material. In some embodiments, the second substrate is in beaded form.

[0032] In some embodiments, the method comprises: (f) casting a layer of the slurry onto the composite substrate of (e) to form a wet-layered composite substrate; and (g) drying the wet layered composite substrate to form a layered composite substrate having embedded therein a second substrate material in the form of beads, rods or spheres. Further includes:

[0033] In some embodiments, the second substrate is in the form of a bead.

[0034] In another aspect, a composite substrate as disclosed herein, a heat source configured to heat an aerosol precursor composition in the substrate to form an aerosol, and an aerosol pathway extending from the substrate to an oral end of the aerosol delivery device is provided.

[0035] In some embodiments, the heat source comprises either an electric heating element or a combustible ignition source. In some embodiments, the heat source is a combustible ignition source comprising a carbon-based material. In some embodiments, the heat source is an electric heating element. In some embodiments, the aerosol delivery device further comprises a power source electronically connected to the heating element. In some embodiments, the aerosol delivery device further comprises a controller configured to control power delivered by the power source to the heating element.

[0036] The present disclosure includes, without limitation, the following embodiments.

[0037] Embodiment 1: A composite substrate configured for use in an aerosol delivery device, comprising: a first substrate material comprising a first filler material, a binder, and an aerosol-forming material; and a second substrate material attached to the first substrate material, the second substrate material comprising a second filler material, a second binder, and a second aerosol-forming material. A composite substrate comprising:

[0038] Embodiment 2: A composite substrate as described in embodiment 1, wherein the second substrate material is in the form of one or more beads, spheres, or rods that are adhered to or embedded within the first substrate material.

[0039] Embodiment 3: The composite substrate of embodiment 1 or 2, wherein the first substrate material is in the form of a sheet.

[0040] Embodiment 4: The composite substrate of embodiment 1 or 2, wherein the first substrate material is in the form of a strip or particulate material.

[0041] Embodiment 5: A composite substrate as described in embodiment 1, wherein both the first and second substrate materials are in the form of sheets attached together in a layered configuration.

[0042] Embodiment 6: The composite substrate of any one of embodiments 1 to 5, wherein the first substrate material and the second substrate material have one or more of different compositions, different densities, and different outer geometries.

[0043] Embodiment 7: The composite substrate of embodiment 6, wherein the density of the second substrate material is at least about 10% higher than the density of the first substrate material.

[0044] Embodiment 8: The composite substrate of any one of embodiments 1-7, wherein the first substrate material comprises at least about 50% by weight of the first filler, based on the total dry weight of the first substrate material.

[0045] Embodiment 9: The composite substrate of any one of embodiments 1 to 8, wherein the first substrate material comprises about 50% to about 75% by weight of the first filler, based on the total dry weight of the first substrate material.

[0046] Embodiment 10: The composite substrate according to any one of embodiments 1 to 9, wherein the first filler and the second filler are independently selected from the group consisting of tobacco materials, plant materials, wood pulp, natural or modified starches, maltodextrins, glucose, calcium carbonate, sugar alcohols, microcrystalline cellulose, and combinations thereof.

[0047] Embodiment 11: The composite substrate of any one of embodiments 1 to 10, wherein the first filler and the second filler are independently selected from the group consisting of tobacco materials, wood pulp, maltodextrin, calcium carbonate, and combinations thereof.

[0048] Embodiment 12: The composite substrate of any one of embodiments 1 to 10, wherein the first filler and the second filler are independently selected from the group consisting of wood pulp, maltodextrin, calcium carbonate, and combinations thereof.

[0049] Embodiment 13: The composite substrate according to any one of embodiments 1 to 12, wherein the first binder and the second binder comprise a cellulose ether independently selected from the group consisting of methyl cellulose, hydroxypropyl cellulose (HPC), hydroxypropyl methyl cellulose (HPMC), hydroxyethyl cellulose, carboxymethyl cellulose (CMC), and combinations thereof.

[0050] Embodiment 14: The composite substrate of any one of embodiments 1 to 13, wherein the first binder and the second binder comprise CMC.

[0051] Embodiment 15: The composite substrate of any one of embodiments 1 to 15, wherein the first aerosol-forming material and the second aerosol-forming material are independently selected from the group consisting of water, polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, cannabinoids, terpenes, sugar alcohols, and combinations thereof.

[0052] Embodiment 16: The composite substrate of any one of embodiments 1 to 15, wherein the first aerosol-forming material and the second aerosol-forming material each comprise a polyhydric alcohol.

[0053] Embodiment 17: The composite substrate of embodiment 16, wherein the polyhydric alcohol is selected from the group consisting of glycerin, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, triacetin, and combinations thereof.

[0054] Embodiment 18: A first substrate material comprising: a tobacco material in an amount of about 0% to about 70% by weight based on the total wet weight of the first substrate material; wood pulp in an amount of about 0% to about 10% by weight, based on the total wet weight of the first substrate material; Calcium carbonate in an amount of about 0% to about 30% by weight based on the total wet weight of the first substrate material, maltodextrin in an amount of about 0% to about 40% by weight, based on the total wet weight of the first substrate material; glycerin in an amount of about 10% to about 20% by weight, based on the total wet weight of the first substrate material; Carboxymethylcellulose in an amount of about 5% to about 15% by weight based on the total wet weight of the first substrate material; and Water in an amount of up to about 30% by weight based on the total wet weight of the first substrate material. The composite substrate according to any one of embodiments 1 to 17, comprising:

[0055] Embodiment 19: The composite substrate of any one of embodiments 1 to 18, wherein the first substrate material further comprises a flavoring agent, an active ingredient, a tobacco extract, or a combination thereof.

[0056] Embodiment 20: The composite substrate of any one of embodiments 1 to 19, wherein the active ingredient comprises a nicotine ingredient.

[0057] Embodiment 21: The composite substrate of any one of embodiments 1 to 20, wherein the beads, spheres, or rods comprise at least about 50% by weight of the second filler, based on the total dry weight of the beads.

[0058] Embodiment 22: The composite substrate of any one of embodiments 1 to 21, wherein the beads, spheres or rods comprise about 50% to about 65% by weight of the second filler, based on the total dry weight of the beads.

[0059] Embodiment 23: The composite substrate of any one of embodiments 1 to 22, wherein the second filler comprises tobacco material, plant material, calcium carbonate, or a combination thereof.

[0060] Embodiment 24: The composite substrate of any one of embodiments 1 to 23, wherein the second filler is selected from the group consisting of tobacco materials, calcium carbonate, and combinations thereof.

[0061] Embodiment 25: The composite substrate according to any one of embodiments 1 to 24, wherein the second binder is selected from the group consisting of methyl cellulose, hydroxypropyl cellulose (HPC), hydroxypropyl methyl cellulose (HPMC), hydroxyethyl cellulose, carboxymethyl cellulose (CMC), and combinations thereof.

[0062] Embodiment 26: The composite substrate of any one of embodiments 1 to 25, wherein the second binder is CMC.

[0063] Embodiment 27: The beads, spheres or rods are tobacco material in an amount of about 20% to about 40% by weight, based on the total dry weight of the bead, sphere, or rod; Calcium carbonate in an amount of about 20% to about 40% by weight, based on the total dry weight of the bead, sphere, or rod; glycerin in an amount of about 0% to about 20% by weight, based on the total dry weight of the bead, sphere, or rod; and Carboxymethylcellulose in an amount of about 0% to about 2% by weight based on the total dry weight of the bead, sphere, or rod. The composite substrate according to any one of embodiments 1 to 26, comprising:

[0064] Embodiment 28: The composite substrate of any one of embodiments 1 to 27, wherein the beads, spheres or rods further comprise a flavoring agent, an active ingredient, or a combination thereof.

[0065] Embodiment 29: The composite substrate described in any one of embodiments 1 to 28, wherein the second aerosol-forming material is selected from the group consisting of water, polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, cannabinoids, terpenes, sugar alcohols, and any combination thereof.

[0066] Embodiment 30: The composite substrate according to any one of embodiments 1 to 29, wherein the polyhydric alcohol is selected from the group consisting of glycerol, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, triacetin, and combinations thereof.

[0067] Embodiment 31: The composite substrate of any one of embodiments 1 to 30, comprising about 10% to about 50% by weight of beads, spheres, or rods, based on the total weight of the composite substrate.

[0068] Embodiment 32: The composite substrate according to any one of embodiments 1 to 31, wherein the beads, spheres or rods have a diameter in the range of about 0.1 mm to about 5 mm.

[0069] Embodiment 33: A composite substrate according to any one of embodiments 1 to 32, wherein the beads, spheres or rods are adhered to the surface of the first substrate material in a randomly arranged pattern.

[0070] Embodiment 34: A composite substrate according to any one of embodiments 1 to 33, wherein the beads, spheres or rods are adhered to the surface of the first substrate material in a uniformly arranged pattern.

[0071] Embodiment 35: The composite substrate of any one of embodiments 1-34, wherein the substrate is substantially free of wood fibers.

[0072] Embodiment 36: The composite substrate of any one of embodiments 1 to 35, wherein the substrate is substantially free of tobacco material.

[0073] Embodiment 37: The composite substrate according to any one of embodiments 1 to 36, in the form of a flat sheet, a gathered sheet, a multi-layer sheet, a rolled sheet, or a strip.

[0074] Embodiment 38: The composite substrate according to any one of embodiments 1 to 36, in strip form, further blended with tobacco material.

[0075] Embodiment 39: An aerosol delivery device comprising: The composite substrate according to any one of embodiments 1 to 38, a heat source configured to heat the composite substrate to form an aerosol; and An aerosol pathway extending from the composite substrate to the mouth end of the aerosol delivery device. 13. An aerosol delivery device comprising:

[0076] Embodiment 40: An aerosol delivery device as described in embodiment 39, wherein the heat source comprises either an electric heating element or a combustible ignition source.

[0077] Embodiment 41: The aerosol delivery device of embodiment 40, wherein the heat source is a combustible ignition source comprising a carbon-based material.

[0078] Embodiment 42: The aerosol delivery device described in embodiment 40, wherein the heat source is an electric heating element.

[0079] Embodiment 43: The aerosol delivery device described in embodiment 42, further comprising a power source electronically connected to the heating element.

[0080] Embodiment 44: The aerosol delivery device described in embodiment 43, further comprising a controller configured to control the power delivered by the power source to the heating element.

[0081] Embodiment 45: A method of making a composite substrate configured for use in an aerosol delivery device, comprising: (a) preparing a slurry comprising a first filler material, a first binder, and a first aerosol-forming material; (b) casting the slurry onto a support device to form a first substrate material in the form of a wet sheet; (c) preparing a second substrate material comprising a second filler material, a second binder, and a second aerosol-forming material, wherein the second substrate material is in a beaded form; (d) depositing a second substrate material onto a surface of the first substrate material; and (e) drying the first substrate material onto which the second substrate material in beaded form has been deposited to form a composite substrate, the second substrate material in beaded form being adhered to a surface of the first substrate material. A method comprising:

[0082] Embodiment 46: The slurry comprises: tobacco or plant material in an amount of about 0% to about 70% by weight, based on the total wet weight of the slurry; wood pulp in an amount of about 0% to about 10% by weight based on the total wet weight of the slurry; an additional first filler in an amount of about 0% to about 70% by weight based on the total wet weight of the slurry, the additional first filler comprising a native or modified starch, maltodextrin, glucose, calcium carbonate, a sugar alcohol, microcrystalline cellulose, or a combination thereof; a first aerosol-forming material in an amount of about 10% to about 20% by weight, based on the total wet weight of the slurry; a cellulose ether in an amount of about 5% to about 15% by weight based on the total wet weight of the slurry, and Water in an amount of up to about 30% by weight based on the total wet weight of the slurry 46. ​​The method of embodiment 45, comprising:

[0083] Embodiment 47: A second substrate material in beaded form, tobacco or plant material in an amount of about 20% to about 40% by weight based on the total dry weight of the second substrate material; an additional second filler in an amount of about 20% to about 40% by weight, based on the total dry weight of the second substrate material; a second aerosol forming agent in an amount of about 0% to about 20% by weight, based on the total dry weight of the second substrate material; and A cellulose ether in an amount of about 0% to about 2% by weight based on the total dry weight of the second substrate material. 47. The method of embodiment 46, comprising:

[0084] Embodiment 48: (f) casting a layer of the slurry onto the composite substrate of (e) to form a wet layered composite substrate; and (g) drying the wet layered composite substrate to form a layered composite substrate having embedded therein a second substrate material in bead-like form. 47. The method of embodiment 46, further comprising:

[0085] These and other features, aspects and advantages of the present disclosure will become apparent upon reading the following detailed description 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.

[0086] 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]

[0087] [Figure 1] 1 illustrates a perspective view of an aerosol delivery device including a controller and an aerosol generating component, the aerosol generating component and the controller connected to each other, according to an exemplary embodiment of the present disclosure. [Diagram 2] 2 illustrates a perspective view of the aerosol delivery device of FIG. 1, with the aerosol generating components and the control device separated from each other, according to an exemplary embodiment of the present disclosure. [Diagram 3] FIG. 1 illustrates a schematic perspective view of an aerosol generating component according to an exemplary embodiment of the present disclosure. [Figure 4] 1 illustrates a schematic cross-sectional view of a substrate portion of an aerosol-generating component according to an exemplary embodiment of the present disclosure. [Diagram 5] 1 illustrates a perspective view of an aerosol-generating component according to an exemplary embodiment of the present disclosure. [Figure 6] 6 illustrates a perspective view of the aerosol-forming component of FIG. 5 with the outer packaging removed, according to one embodiment of the present disclosure. [Figure 7] 1 is a photograph of an exemplary composite substrate having a plurality of beads adhered to a first substrate material in the form of a sheet, according to one embodiment of the present disclosure. [Figure 8] 1 is a photograph of another exemplary composite substrate in which a plurality of beads are adhered to a first substrate material in the form of a sheet, according to an embodiment of the present disclosure. [Figure 9] 1 is a photograph of yet another exemplary composite substrate having a plurality of beads adhered to a first substrate material in the form of a sheet, according to an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0088] The present disclosure will now be described more fully hereinafter with reference to exemplary embodiments thereof. These exemplary embodiments are described so that the disclosure will be full and complete, and will fully convey the scope of the disclosure to those skilled in the art. Indeed, the disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that the disclosure will meet applicable legitimate requirements. As used in this specification and claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. References to "dry weight percent" or "dry weight basis" refer to weight based on dry ingredients (i.e., all ingredients except water). References to percentages are intended to mean weight percent unless otherwise indicated. As used herein, "substantially free" refers to a concentration of a given substance of less than 1% by weight, or less than 0.5% by weight, or less than 0.1% by weight, based on the total weight of the material. References to percentages are intended to mean weight percent unless otherwise indicated.

[0089] I. Composite base material As described herein below, an exemplary embodiment of the present disclosure relates to a composite substrate configured for use in an aerosol delivery device. The substrate comprises a first substrate material and a second substrate material. The second substrate material is attached to the first substrate material. Each of the first and second substrate materials can include, for example, ingredients, such as fillers, binders, aerosol-forming materials, flavorings, and active ingredients, which are independently selected for each of the first and second substrate materials. Each of these ingredients, along with additional substrate ingredients, are further described herein below.

[0090] filling material The substrate disclosed herein comprises a filler material in each of the first substrate material and the second substrate material. The filler material is independently selected for each of the first substrate material and the second substrate material. Suitable fillers include, but are not limited to, tobacco materials, plant materials, starches, sugars, sugar alcohols, wood fibers, inorganic materials, inert materials, and the like. Examples of suitable fillers are further described herein below.

[0091] Starch In some embodiments, the filler comprises starch, including native and modified starch. "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, and thus starches exhibit certain functional application properties. A particular starch can be selected for inclusion in the beaded substrate, for example, based on the ability of the starch material to impart certain sensory properties to the beads. Starches from various sources can be used. For example, major sources of starch include cereal grains (e.g., rice, wheat, oats, barley, rye, and corn) and root crops (e.g., potato and cassava). Other examples of starch sources include acorns, arrowroot, arracacha, banana, barley, legumes (e.g., fava, lentil, mung bean, bean, chickpea), breadfruit, buckwheat, canna, chestnut, taro, dogtooth violet, kudzu, malanga, t, oka, yam, sago, sorghum, millet, sweet potato, quinoa, tapioca, taro, tobacco, water chestnut, and yam. Suitable starches include, but are not limited to, corn starch, rice starch, and edible modified starches. Certain starches are modified starches. Modified starches have one or more structural modifications, often designed to alter their high heat 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 or base catalysis or oxidation in the presence of a base, bleaching, transglycosylation and depolymerization (e.g., dextrinization in the presence of a catalyst), crosslinking, enzyme 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.

[0092] Cellulosic Materials In some embodiments, the filler comprises a cellulosic material, such as microcrystalline cellulose ("mcc"). The mcc may be synthetic or semi-synthetic, or may be derived entirely from natural cellulose. The mcc may 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. In some embodiments, the cellulosic material is wood fiber, wood-derived fiber, or ground / powdered cellulose.

[0093] tobacco In some embodiments, the filler material comprises 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, N. pratense N. plumbaginifolia, N. raimondii, N. rosulata, N. simulans, N. stocktonii, N. suaveolens, N. umbratica, N. velutina, N. wigandioides, N. acaulis, N. acuminata, N.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.

[0094] 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.

[0095] 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.

[0096] Various parts or portions of a plant of a species of the Nicotiana genus may be included within the substrates disclosed herein. For example, substantially all of the plant (e.g., the entire plant) can be harvested and utilized as is. Alternatively, various parts or pieces of the plant can be harvested or separated for further use after harvest. For example, flowers, leaves, stems, stalks, roots, seeds, and various combinations thereof can be isolated for further use or processing. In some embodiments, the milled tobacco material comprises tobacco leaf (lamina). The substrates disclosed herein can include 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.

[0097] Tobacco materials are typically used in a form that can be described as particulate (i.e., in shredded, ground, granulated or powder form). Most preferably, the tobacco material is 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.

[0098] 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 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, 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.

[0099] For the preparation of substrates (e.g., base materials and beaded materials), it is typical to subject harvested plants of Nicotiana species to a drying process. The tobacco materials incorporated into the substrates disclosed herein are generally appropriately cured and / or aged materials. Descriptions of different types of curing processes for different types of tobacco are 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.

[0100] 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.

[0101] 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.

[0102] 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.

[0103] 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 milled 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 weight of the tobacco material.

[0104] Tobacco-derived materials In some embodiments, the filler comprises a tobacco-derived material, e.g., 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 are described in 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; and S. No. 4,605,016 by Oga 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. 5,020,540 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, No. 301,694; No. 5,318,050 by Gonzalez-Parra et al.; No. 5,343,879 by Teague; No. 5,360,022 by Newton; No. 5,435,325 by Clapp et al.; No. 5,445,169 by Brinkley et al.; No. 6,131,584 by Lauterbach; No. 6,298,859 by Kierulff et al.; No. 6,772,767 by Mua et al.; and No. 7,337,782 by Thompson.

[0105] Non-tobacco plants In some embodiments, the filler material comprises non-tobacco plant material. As used herein, the term "plant ingredient" or "plant" refers to any plant 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."

[0106] Non-limiting examples of botanical materials include, without limitation, acai berry, alfalfa, allspice, angelica root, anise (e.g., star anise), annatto seed, apricot oil, bacopa monniera, basil, bee balm, beetroot, bergamot, black cohosh, black pepper, black tea, blueberry, borage, ambrosia, cacao, calamus root, hemp / marijuana, caraway seed, catnip, catuaba, cayenne, cayenne pepper, chaga, chamomile, chervil, chocolate, cinnamon, clary sage, clove, coffee, comfrey, coriander seed, cranberry, dandelion, echinacea, elderberry, elderberry, evening primrose, eucalyptus, fennel, feverfew, garlic, ginger, ginkgo biloba, and the like. biloba), ginseng, goji berry, goldenseal, grape seed, grapefruit, green tea, gotu kola, hawthorn, hibiscus flower, honeybush, gynostemma, kava, jasmine, lavender, licorice, lilac, yamabushitake mushroom, marjoram, milk thistle, mint, oolong tea, orange, oregano, papaya, pennyroyal mint, peppermint (Mentha piperita), potato skins, quince, red clover, rooibos (red or green), rose hips, rosemary, sage, St. John's wort, savory, saw palmetto, silybum marianum marianum, slippery elm bark, high tannin sorghum bran, high tannin sorghum grain, spearmint, spirulina, sumac bran, thyme, turmeric, bearberry, valerian, wild yam root, wintergreen, withania somnifera, yacon root, yellow dock, yerba mate, and yerba santa.

[0107] In some embodiments, the non-tobacco plant material is milled. In some embodiments, the milled non-tobacco plant material comprises eucalyptus, rooibos, star anise, fennel, or combinations thereof.

[0108] The milled form of the non-tobacco plant material can have a range of particle sizes. For example, in some embodiments, the milled non-tobacco plant material has a particle size of about 0.05 mm to about 1 mm. In some cases, the non-tobacco plant material particles can be sized to pass through a screening mesh to obtain the required particle size range.

[0109] In some embodiments, the non-tobacco plant material is present in the form of an extract. "Plant extract" as used herein refers to an isolated component of the plant material that is extracted from the solid plant material by a solvent (e.g., water, alcohol, etc.) that is contacted with the solid plant material in an extraction process. Various extraction techniques of solid plant materials can be used to obtain plant material extracts. In some embodiments, the plant extract is an extract of angelica root, caraway seed, cinnamon, clove, coriander seed, elderberry, elderberry, ginger, jasmine, lavender, lilac, peppermint (Mentha piperita), quince, or a combination thereof.

[0110] Inorganic / inert substances In some embodiments, the filler comprises an inorganic or inert material, such as, but not limited to, chitosan, carbon (graphite, diamond, fullerenes, graphene), quartz, granite, diatomaceous earth, calcium carbonate, calcium phosphate, clay, crustacean and other marine shells, or combinations thereof, hi some embodiments, the filler comprises calcium carbonate.

[0111] Sugars and sugar alcohols In some embodiments, the filler comprises a sugar. Examples of suitable sugars include, but are not limited to, glucose, maltose, maltotriose, galactose, and lactose. In some embodiments, the filler comprises a sugar alcohol. Sugar alcohols are polyols derived from monosaccharides or disaccharides, having a partially or fully hydrogenated form. Sugar alcohols, for example, have from about 4 to about 20 carbon atoms and include erythritol, arabitol, ribitol, isomalt, maltitol, dulcitol, iditol, mannitol, xylitol, lactitol, sorbitol, and combinations thereof (e.g., hydrogenated starch hydrolysates).

[0112] Binder The substrates disclosed herein include a binder in the first substrate material, the second substrate material, or both. A variety of binders can be used to help maintain the integrity of the first substrate material, the second substrate material, or both intact. The binder is selected independently for each of the first substrate material and the second substrate material. Typical binders can be organic or inorganic or combinations thereof. Representative binders include, but are not limited to, polymers such as povidone, sodium alginate, pectin, gum, carrageenan, pullulan, xanthan, agar, acacia, zein, cellulose derivatives, and the like, and combinations thereof. Other examples of binder materials are described, for example, in U.S. Patent No. 5,101,839 to Jakob et al.; and U.S. Patent No. 4,924,887 to Raker et al., each of which is incorporated herein by reference in its entirety.

[0113] In some embodiments, the binder is an alginate, such as ammonium alginate, propylene glycol alginate, potassium alginate, or sodium alginate. Alginates, especially high viscosity alginates, can be utilized in conjunction with controlled levels of free calcium ions. In some embodiments, the binder comprises carrageenan. In some embodiments, the binder comprises agar.

[0114] In some embodiments, the binder is a gum, such as 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, gum ghatti, gum tragacanth, 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, gum tragacanth, or combinations thereof. Other suitable gums include modified gums, such as hydroxyethyl guar, hydroxypropyl guar, hydroxyethyl locust bean gum, or hydroxypropyl locust bean gum.

[0115] In some embodiments, the binder is a pectin, such as fruit, citrus, or tobacco pectin. Pectin is generally known to act as a hygroscopic agent that promotes retention of moisture.

[0116] In some embodiments, the binder is a cellulose derivative. In some embodiments, the cellulose derivative is a cellulose ether, which means 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. In some embodiments, the cellulose derivative is a hydroxyalkyl cellulose ether. Non-limiting examples of such cellulose derivatives include methylcellulose, hydroxypropylcellulose ("HPC"), hydroxypropylmethylcellulose ("HPMC"), and hydroxyethylcellulose. 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.

[0117] Aerosol-forming materials The substrates disclosed herein include an aerosol-forming material in the first substrate material, the second substrate material, or both. The aerosol-forming material is independently selected for each of the first substrate material and the second substrate 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 include water, polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, terpenes, 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.

[0118] Polyhydric alcohol In some embodiments, the aerosol-forming material comprises one or more polyhydric alcohols. Examples of polyhydric alcohols include glycerol, propylene glycol, and other glycols, such as 1,3-propanediol, diethylene glycol, and triethylene glycol. In some embodiments, the polyhydric alcohol is selected from the group consisting of glycerol, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, triacetin, and combinations thereof.

[0119] 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.

[0120] 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 may be desirable if the user is in a public place where they do not want to produce a large plume of "smoke" (i.e. vapor). Conversely, if 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.

[0121] 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).

[0122] Fatty acids, esters and waxes In some embodiments, the aerosol-forming material comprises one or more fatty acids. The fatty acids may include short chain, long chain, saturated, unsaturated, straight chain, or branched chain carboxylic acids. The fatty acids may 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.

[0123] 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.

[0124] 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.

[0125] 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. 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.

[0126] 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.

[0127] active ingredient In some embodiments, the substrates disclosed herein can include one or more active ingredients in the first substrate material, the second substrate material, or both. The active ingredients can be added as a component of the aerosol-forming material, the first substrate material, or the second substrate material, or can be added separately (e.g., impregnated into the substrate after formation). The active ingredients can be independently selected for each of the first substrate material and the second substrate material. As used herein, "active ingredient" refers to one or more substances that belong to any of the following categories: APIs (active pharmaceutical substances), food additives, herbal materials, natural medicines, and naturally occurring substances that can have an action on humans. The active ingredient can be any known agent adapted for therapeutic, prophylactic, or diagnostic use. These may include, for example, synthetic organic compounds, proteins and peptides, polysaccharides and other sugars, lipids, inorganic compounds, and nucleic acid sequences that have therapeutic, prophylactic, or diagnostic activity. Active ingredients include, but are not limited to, nicotine, botanical ingredients (e.g., lavender, peppermint, chamomile, basil, rosemary, ginger, hemp, ginseng, maca, and tisane) and / or cannabinoids, such as tetrahydrocannabinol (THC) and cannabidiol (CBD). The specific percentages and ingredient selections will vary depending on the flavor, texture, and other characteristics desired. 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 or other animal 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).

[0128] The amount of active ingredient present may vary, and when present, is generally less than about 30% or less than about 20% of the total weight of the substrate. For example, the active ingredient may be present in an amount from about 0.1%, about 0.5%, about 1%, or about 5% to about 10%, about 20%, or about 30% of the total weight of the substrate.

[0129] Herbal Ingredients In some embodiments, the active ingredient comprises one or more herbal materials. For the purposes of this disclosure, the term "herbal materials" refers to seed-bearing plants that do not produce persistent xylem tissue and are often valued for their medicinal or sensory properties (e.g., tea or tisane). Certain herbal materials, either as plant materials or extracts thereof, have found use in traditional herbal medicine. Non-limiting examples of herbal materials or materials derived from herbs include cannabis, eucalyptus, rooibos, fennel, citrus, clove, lavender, peppermint, chamomile, basil, rosemary, ginger, turmeric, green tea, white mulberry, hemp, cocoa, ashwagandha, baobab, chlorophyll, cordyceps, damiana, ginseng, guarana, and maca.

[0130] Nicotine content In certain embodiments, the active ingredient comprises a naturally occurring or synthetic nicotine component. By "nicotine component" is meant any suitable form of nicotine (e.g., free base or salt) that provides oral absorption of at least a portion of the nicotine present. The nicotine may be tobacco derived (e.g., tobacco extract) or non-tobacco derived (e.g., synthetic or otherwise obtained). Most preferably, the nicotine is naturally occurring and obtained as an extract from a species of the genus Nicotiana (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 or essentially pure form. Highly preferred nicotine utilized has a purity of greater than about 95 percent by weight, more preferably greater than about 98 percent, and most preferably greater than about 99 percent.

[0131] Typically, the nicotine component is selected from the group consisting of nicotine free base and nicotine salt.In some embodiments, the nicotine component is nicotine in its free base form, and can be easily adsorbed onto, for example, microcrystalline cellulose material to form a microcrystalline cellulose-nicotine carrier complex.See, for example, the discussion of nicotine in free base form in Hansson's US Patent Publication No. 2004 / 0191322, which is incorporated herein by reference.

[0132] In some embodiments, at least a portion of the nicotine component can be utilized in the form of a salt. The nicotine salt can be provided using the types of ingredients and techniques described in U.S. Patent No. 2,033,909 to Cox et al. and Perfetti, Beitrage Tabakforschung Int., vol. 12: 43-54 (1983), which are incorporated herein by reference. Additionally, nicotine salts are available from sources such as Pfaltz and Bauer, Inc. and K&K Laboratories, Division of ICN Biochemicals, Inc. Typically, the nicotine component is selected from the group consisting of nicotine free base, nicotine salts, such as hydrochloride, dihydrochloride, monotartrate, bitartrate, sulfate, salicylate, and nicotine zinc chloride.

[0133] In some embodiments, at least a portion of the nicotine can be in the form of a resin complex of nicotine, in which the nicotine is bound to an ion exchange resin, such as nicotine polacrilex, which is nicotine bound to a polymethacrylic acid, such as Amberlite IRP64, Purolite C115HMR, or Doshion P551. See, for example, U.S. Patent No. 3,901,248 to Lichtneckert et al., which is incorporated herein by reference. Another example is a nicotine-polyacrylcarbomer complex, such as a complex with Carbopol 974P. In some embodiments, the nicotine may be present in the form of a nicotine polyacryl complex.

[0134] Typically, the nicotine component (calculated as the free base), when present, is at a concentration of at least about 0.001% by weight of the substrate, for example, in the range of about 0.001% to about 10% by weight, based on the total weight of the 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, for example, 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 substrate. In some embodiments, the nicotine component is present in a concentration of from about 0.1% w / w to about 3% by weight, calculated as the free base, based on the total weight of the substrate, e.g., from about 0.1% w / w to about 2.5% by weight, from about 0.1% w / w to about 2.0% by weight, from about 0.1% w / w to about 1.5% by weight, or from about 0.1% w / w to about 1% by weight.

[0135] In some embodiments, the substrate of the present disclosure can be characterized as being completely free or substantially free of any nicotine components (e.g., any embodiment disclosed herein can be completely or substantially free of any nicotine components). By "substantially free" it is meant that no nicotine has been intentionally added beyond trace amounts that may be naturally present, for example, in plants or herbal materials. 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 the free base, based on the total weight of the substrate.

[0136] 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).

[0137] 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 variants (CBNV), cannabiditriol (CBO), tetrahydrocannabmolic acid (THCA), tetrahydrocannabivarinic acid (THCV A), and mixtures thereof.

[0139] In certain embodiments, the cannabinoid is selected from tetrahydrocannabinol (THC), the primary psychoactive compound of cannabis, and cannabidiol (CBD), another major component of the plant, although CBD does not contain psychoactive properties. All of the above compounds can be used in isolated or synthetically derived form from plant material. Certain cannabinoids, including but not limited to CBD and THC, may exist in more than one isomeric form, for example, Δ8- and Δ9-THC. Such isomeric forms may be naturally occurring or synthetic. For the avoidance of doubt, reference to "cannabinoid" within this disclosure is intended to include any and all isomeric forms thereof.

[0140] In some embodiments, the cannabinoid comprises at least tetrahydrocannabinol (THC). In some embodiments, the cannabinoid is tetrahydrocannabinol (THC). In some embodiments, the THC is Δ8-THC. In some embodiments, the THC is Δ9-THC.

[0141] In some embodiments, the cannabinoid comprises at least cannabidiol (CBD). In some embodiments, the cannabinoid is cannabidiol (CBD). In some embodiments, the CBD is synthetic CBD. In some embodiments, the CBD is Δ8-CBD. In some embodiments, the CBD is Δ9-CBD.

[0142] 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.

[0143] 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 oral product is about 1% or less by weight of the oral product, such as about 0.5% or less by weight of the oral product, for example about 0.1% or less by weight of the oral product, for example about 0.01% or less by weight of the oral product.

[0144] Selection of cannabinoids and their specific percentages that may be present in the substrate. In some embodiments, the cannabinoid (e.g., CBD) is present at a concentration of at least about 0.001% by weight of the substrate, for example, in the range of about 0.001% to about 2% by weight of the substrate. In some embodiments, the cannabinoid (e.g., CBD) is present 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 at a concentration of about 0.4% to about 1.5% by weight based on the total weight of the substrate.

[0145] 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.

[0146] Flavoring agent In some embodiments, the substrates disclosed herein can include one or more flavoring agents, for example, in the first substrate material, the second substrate material, or both. The flavoring agents can be independently selected for each of the first substrate material and the second substrate material. As used herein, reference to a "flavoring agent" refers to a compound or ingredient that can be aerosolized and delivered to a user to impart a sensory experience in terms of taste and / or aroma. Some examples of flavoring agents include, but are not limited to, vanillin, ethyl vanillin, cream, tea, coffee, fruit (e.g., apple, cherry, strawberry, peach, and citrus flavors, including lime and lemon), maple, menthol, mint, peppermint, spearmint, wintergreen, nutmeg, clove, lavender, cardamom, ginger, honey, anise, sage, rosemary, hibiscus, rose hips, yerba mate, guayusa, honeybush, rooibos, yerba santa, bacopa monniera, ginkgo biloba, withania somnifera, cinnamon, sandalwood, jasmine, cascarilla, cocoa, licorice, and flavors and flavor packages of the type and nature customarily used for flavoring cigarettes, cigars, and pipe tobacco. In some embodiments, the flavoring agent comprises a berry, clove, or citrus flavor and / or aroma.

[0147] Syrups, such as 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 to Dube et al. and U.S. Patent Application Publication No. 2012 / 0152265, both of which are incorporated herein by reference in their entirety. The selection of such additional ingredients 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. This disclosure is intended to encompass any such additional ingredients that are readily apparent to those skilled in the art of tobacco and tobacco-related or tobacco-derived products. See, for example, Gutcho, Tobacco Flavoring Substances and Methods, Noyes Data Corp. (1972) and Leffingwell et al., Tobacco Flavoring for Smoking Products (1972), the disclosures of which are incorporated herein by reference in their entirety. It should be noted that reference to a flavoring agent 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 Publication No. 2019 / 0082735 to Phillips et al., which is incorporated herein by reference in its entirety.

[0148] 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 substrate, based on the total weight of the substrate.For example, the flavoring agent can be present in an amount of about 0.1%, about 0.5%, about 1%, or about 5% by weight, based on the total wet weight of the substrate, to about 10%, about 20%, or about 30% by weight of the substrate.In some embodiments, the flavoring agent is present in an amount of about 1% to about 5% or about 1% to about 3% by weight, based on the total wet weight of the substrate.

[0149] Other Ingredients 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) has independent desirable 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.

[0150] 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 an aluminum material, a stainless steel material, a copper material, a carbon material, and a graphite material. In some embodiments, one or more conductive fibers or particles having different Curie temperatures may be included in the substrate material to facilitate induction heating at different temperatures.

[0151] 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.

[0152] Any of the above-mentioned other ingredients may be included in the first substrate material, the second substrate material, or both. In addition to or instead of any of the above, other ingredients may also be combined with the substrate (e.g., as a physical mixture).

[0153] First Substrate Material The composite substrate disclosed herein comprises a first substrate material. By "first substrate material" is meant a portion of the composite substrate to which a second substrate material is attached. The first substrate material comprises a filler, a binder, and an aerosol-forming material, each of which is as described herein above. The filler, binder, and aerosol-forming material of the first substrate material are distinguished from the filler, binder, and aerosol-forming material of the second substrate material by being referred to as the first filler, first binder, and first aerosol-forming material, respectively, which may be the same or different within each material.

[0154] The physical form of the first substrate material may vary. For example, in some embodiments, the first substrate material is in the form of a strip or particulate material. In some embodiments, the first substrate material is in the form of a sheet.

[0155] The physical properties (e.g., size and density) of the first substrate material may vary depending on its physical form, components and amounts. In some embodiments, the first substrate material has a density of 0.20 g / cm 3 ~1.2g / cm 3 In some embodiments, the first substrate material has a thickness in the range of about 0.1 mm to about 1.5 mm.

[0156] The amount of the first filler present in the first substrate material may vary. In some embodiments, the first substrate material comprises at least about 50% by weight of the first filler, based on the total dry weight of the first substrate material. In some embodiments, the first substrate material comprises from about 50% to about 75% by weight of the first filler, based on the total dry weight of the first substrate material, for example, about 50%, about 55%, about 60%, about 65%, about 70% or about 75% by weight of the first filler, based on the total dry weight of the first substrate material.

[0157] In some embodiments, the first filler comprises tobacco material, plant material, wood pulp, natural or modified starch, maltodextrin, glucose, calcium carbonate, sugar alcohol, microcrystalline cellulose, or combinations thereof. In some embodiments, the first filler is selected from the group consisting of tobacco material, wood pulp, maltodextrin, calcium carbonate, and combinations thereof. In some embodiments, the first filler is selected from the group consisting of wood pulp, maltodextrin, calcium carbonate, and combinations thereof.

[0158] In some embodiments, the first filler comprises a tobacco material, e.g., milled tobacco. The amount of tobacco material present in the first substrate material may vary and is generally less than about 70% by weight of the first substrate material, based on the total dry weight of the first substrate material. For example, the tobacco material can be present in an amount of about 30%, about 35%, about 40%, about 45% or about 50% to about 55%, about 60% or about 65% by weight of the first substrate material, based on the total dry weight of the first substrate material. In some embodiments, the tobacco is present in an amount of about 30% to about 70% or about 30% to about 50% by weight, based on the total dry weight of the first substrate material. In some embodiments, the tobacco is present in an amount of about 50% to about 65% by weight, based on the total dry weight of the first substrate material. In other embodiments, the first substrate material is substantially free or completely free of tobacco material. By "substantially free" of tobacco material, it is meant that no tobacco material has been intentionally added beyond trace amounts that may be naturally present, for example, in a plant or other plant material. For example, certain embodiments may be characterized as having less than 0.1 dry weight percent, or less than 0.01 dry weight percent, or less than 0.001 dry weight percent, or 0 dry weight percent tobacco material, based on the total dry weight of the first substrate material.

[0159] In some embodiments, the first filler comprises wood pulp. The amount of wood pulp present in the first substrate material may vary and is generally less than about 15% by weight of the first substrate material, based on the total dry weight of the first substrate material. For example, wood pulp can be present in an amount of about 5% to about 10% by weight of the first substrate material, based on the total dry weight of the first substrate material. In other embodiments, the first substrate material is substantially free 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 first substrate material.

[0160] In some embodiments, the first filler comprises calcium carbonate. The amount of calcium carbonate can vary and is generally less than about 35% by weight of the first substrate material, based on the total dry weight of the first substrate material. For example, calcium carbonate can be present in an amount of about 20%, about 25% or about 30% by weight of the first substrate material, based on the total dry weight of the first substrate material.

[0161] In some embodiments, the first filler material is tobacco or plant material in an amount of about 0% to about 70% by weight, based on the total wet weight of the first substrate material; wood pulp in an amount of about 0% to about 10% by weight, based on the total wet weight of the first substrate material; calcium carbonate in an amount of about 0% to about 30% by weight, based on the total wet weight of the first substrate material; and Maltodextrin in an amount of about 0% to about 40% by weight based on the total wet weight of the first substrate material. Includes.

[0162] The amount of the first binder present in the first substrate material may vary. In some embodiments, the first substrate material comprises about 5% to about 15% by weight of the first binder, based on the total wet weight of the first substrate material. In some embodiments, the first binder is a cellulose ether. In some embodiments, the cellulose ether is selected from the group consisting of methylcellulose, hydroxypropylcellulose (HPC), hydroxypropylmethylcellulose (HPMC), hydroxyethylcellulose, carboxymethylcellulose (CMC), and combinations thereof. In some embodiments, the binder is CMC. In some embodiments, the first substrate material comprises about 5%, about 6%, about 7%, about 8%, about 9%, about 10%, about 11%, about 12%, about 13%, about 14%, or about 15% by weight of CMC, based on the total wet weight of the first substrate material.

[0163] The amount of the first aerosol-forming material present in the first substrate material may vary. In general, the amount of aerosol-forming material present in the entire substrate is such that the substrate provides acceptable sensory properties and desirable performance characteristics. For example, in certain embodiments, a sufficient amount of aerosol-forming material is utilized to provide the production of a visible mainstream aerosol that is similar in appearance to tobacco smoke in many respects. The amount of aerosol-forming material present may depend on factors such as the number of puffs desired per aerosol-generating component. The total amount of aerosol-forming material may be divided between the first substrate material and the second substrate material, or may be present only in a single material.

[0164] In some embodiments, the first substrate material comprises the first aerosol-forming material in an amount of about 20% by weight or less, e.g., about 5% by weight, about 10% by weight, about 15% by weight, or about 20% by weight, based on the total wet weight of the first substrate material. In some embodiments, the first substrate material comprises the first aerosol-forming material in an amount of about 10% by weight to about 20% by weight, based on the total wet weight of the first substrate material.

[0165] In some embodiments, the first aerosol-forming material comprises water, a polyhydric alcohol, a polysorbate, a sorbitan ester, a fatty acid, a fatty acid ester, a wax, a cannabinoid, a terpene, a sugar alcohol, or a combination thereof. In some embodiments, the first aerosol-forming material comprises a polyhydric alcohol. In some embodiments, the polyhydric alcohol is selected from the group consisting of glycerin, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, triacetin, and combinations thereof. In some embodiments, the first aerosol-forming material is glycerin.

[0166] In some embodiments, the first substrate material is a tobacco material in an amount of about 0% to about 70% by weight based on the total wet weight of the first substrate material; wood pulp in an amount of about 0% to about 10% by weight, based on the total wet weight of the first substrate material; calcium carbonate in an amount of about 0% to about 30% by weight, based on the total wet weight of the first substrate material; maltodextrin in an amount of about 0% to about 40% by weight based on the total wet weight of the base material; glycerin in an amount of about 10% to about 20% by weight, based on the total wet weight of the first substrate material; Carboxymethylcellulose in an amount of about 5% to about 15% by weight based on the total wet weight of the first substrate material; and Water in an amount of up to about 30% by weight based on the total wet weight of the first substrate material. Includes.

[0167] In some embodiments, the first substrate material further comprises a flavoring agent, an active ingredient, a tobacco extract, or a combination thereof, hi some embodiments, the active ingredient comprises a nicotine component.

[0168] Second Substrate Material The composite substrate disclosed herein includes a second substrate material. By "second substrate material" is meant a portion of the composite substrate that is attached to the first substrate material. The second substrate material includes a filler, a binder, and an aerosol-forming material (i.e., a second filler, a second binder, and a second aerosol-forming material, to distinguish from the first case, respectively), each of which is as described herein above. In some embodiments, the first and second substrates may be the same material (i.e., have the same composition), but are present in different forms, such as a cast sheet and one or more beads, spheres, rods, etc.

[0169] The physical properties of the second substrate material (e.g., size and density) may vary depending on its physical form, components and amount. In some embodiments, the second substrate material has a mass density of about 0.5 g / cm, as measured by the volume of a cylinder occupied by a given population. 3 ~about 0.8g / cm 3 In some embodiments, the density of the second substrate material is different from the density of the first substrate material. In some embodiments, the density of the first and second substrates is different by at least about 10%, e.g., about 10%, about 15%, or about 20%. In some embodiments, the density of the second substrate material is at least about 10% higher than the density of the first substrate material, e.g., about 10%, about 15%, or about 20% higher. Without wishing to be bound by any particular theory, it is believed that the difference in composition and / or density between the first and second substrate materials results in slower aerosol formation from the denser substrate material, extending the period of use from articles including such composite substrates. For example, when incorporated into the aerosol delivery articles described herein, it is believed that the composite substrates disclosed herein result in a longer lasting and more pleasant consumer experience (e.g., longer and more consistent aerosol formation) than that obtained in the use of conventional articles without the composite substrate.

[0170] The physical form of the second substrate material may be different. For example, in some embodiments, the second substrate material is in the form of a strip material or particulate material. In some embodiments, the second substrate material is in the form of a sheet. In some embodiments, the second substrate material is in the form of one or more beads, spheres, or rods. In some embodiments, the second substrate material is in the form of one or more beads ("beaded material") that are attached to or embedded in the first substrate material. By "beaded material" it is meant that the material is in the form of granules or pellets that can have any of a variety of cross-sectional shapes, including round, spherical, ovoid, or irregular shapes. The beaded material is typically flowable so that the beaded material can be easily deposited, for example, on a sheet of the first substrate material. In some embodiments, the beads are round or spherical. In some embodiments, the beads are between #32 and #4 mesh. In some embodiments, the beads have a diameter ranging from about 0.5 mm to about 5 mm, for example, about 0.5 mm, about 1 mm, about 2 mm, about 3 mm, about 4 mm, or about 5 mm. In some embodiments, the beads are approximately spherical.

[0171] The amount of the second filler present in the second substrate material may vary. In some embodiments, the second substrate material comprises at least about 50% by weight of the second filler, based on the total wet weight of the second substrate material. In some embodiments, the second substrate material comprises about 50% to about 75% by weight of the second filler, based on the total wet weight of the second substrate material, for example, about 50%, about 55%, about 60%, about 65%, about 70% or about 75% by weight of the second filler, based on the total wet weight of the second substrate material. In some embodiments, the second substrate material comprises about 50% to about 65% by weight of the second filler, based on the total wet weight of the second substrate material.

[0172] In some embodiments, the second filler comprises tobacco material, plant material, calcium carbonate, or combinations thereof. In some embodiments, the second filler is selected from the group consisting of tobacco material, calcium carbonate, and combinations thereof.

[0173] In some embodiments, the second filler comprises a tobacco material, for example a milled tobacco material. The amount of tobacco material present in the second substrate material may vary and is generally less than about 50% by weight of the second substrate material, based on the total wet weight of the second substrate material. For example, the tobacco material can be present in an amount of about 20%, about 25%, about 30% or about 35% by weight of the second substrate material, to about 40%, about 45% or about 50% by weight, based on the total wet weight of the second substrate material. In some embodiments, the tobacco material is present in an amount of about 20% to about 40% or about 25% to about 35% by weight, based on the total wet weight of the second substrate material.

[0174] In some embodiments, the second filler comprises calcium carbonate. The amount of calcium carbonate can vary and is generally less than about 50% by weight of the second substrate material, based on the total wet weight of the second substrate material. For example, calcium carbonate can be present in an amount of about 20%, about 25%, about 30%, about 35% or about 40% by weight of the second substrate material, based on the total wet weight of the second substrate material.

[0175] In some embodiments, the second filler material is a tobacco material in an amount of about 20% to about 40% by weight based on the total wet weight of the second substrate material; and Calcium carbonate in an amount of about 20% to about 40% by weight based on the total wet weight of the second substrate material. Includes.

[0176] In some embodiments, the second substrate material further comprises a binder (i.e., a second binder). The amount of the second binder present in the second substrate material may vary. In some embodiments, the second substrate material comprises less than about 5% by weight of the second binder, based on the total wet weight of the second substrate material. In some embodiments, the second substrate material comprises about 0.1% to about 2% by weight, e.g., about 0.5% to about 1% by weight, of the second binder, based on the wet weight of the second substrate material. In some embodiments, the amount of binder present in the second substrate material is less than the amount present in the first substrate material.

[0177] In some embodiments, the second binder is selected from the group consisting of methyl cellulose, hydroxypropyl cellulose (HPC), hydroxypropyl methyl cellulose (HPMC), hydroxyethyl cellulose, carboxymethyl cellulose (CMC), and combinations thereof. In some embodiments, the second binder is a cellulose ether. In some embodiments, the cellulose ether is selected from the group consisting of methyl cellulose, hydroxypropyl cellulose (HPC), hydroxypropyl methyl cellulose (HPMC), hydroxyethyl cellulose, carboxymethyl cellulose (CMC), and combinations thereof. In some embodiments, the second binder is CMC. In some embodiments, the second substrate material comprises about 0.5% to about 2% by weight of CMC, based on the total wet weight of the second substrate material.

[0178] In some embodiments, the second substrate material further comprises a second aerosol-forming material. If present, the amount of the second aerosol-forming material present in the second substrate material may vary. In some embodiments, the second substrate material comprises the second aerosol-forming material in an amount of about 20% by weight or less, e.g., about 5% by weight, about 10% by weight, about 15% by weight, or about 20% by weight, based on the total wet weight of the second substrate material. In some embodiments, the second substrate material comprises the second aerosol-forming material in an amount of about 10% by weight to about 20% by weight, based on the total wet weight of the second substrate material.

[0179] In some embodiments, the second aerosol-forming material comprises water, a polyhydric alcohol, a polysorbate, a sorbitan ester, a fatty acid, a fatty acid ester, a wax, a cannabinoid, a terpene, a sugar alcohol, or a combination thereof. In some embodiments, the second aerosol-forming material comprises a polyhydric alcohol. In some embodiments, the polyhydric alcohol is selected from the group consisting of glycerin, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, triacetin, and combinations thereof. In some embodiments, the aerosol-forming material is glycerin.

[0180] The amount of water present in the second substrate material may vary. For example, in some embodiments, the second substrate material comprises from about 0.1% to about 50% water by weight, based on the total wet weight of the second substrate material. In some embodiments, the second substrate material is dried during preparation to remove at least a portion of the water present. In some embodiments, after drying, the second substrate material comprises less than about 10% water by weight, for example, about 5%, about 1% or about 0.1% water by weight, based on the total wet weight of the second substrate material.

[0181] In some embodiments, the second substrate material is a tobacco material in an amount of about 20% to about 40% by weight, based on the total dry weight of the second substrate material; calcium carbonate in an amount of about 20% to about 40% by weight, based on the total dry weight of the second substrate material; glycerin in an amount of about 0% to about 20% by weight, based on the total dry weight of the second substrate material; and Carboxymethylcellulose in an amount of about 0% to about 2% by weight, based on the total dry weight of the second substrate material. Includes.

[0182] In some embodiments, the second substrate material further comprises a flavoring agent, an active ingredient, or a combination thereof. In some embodiments, the second substrate material comprises about 10% to about 50% by weight of a flavoring agent, based on the total wet weight of the second substrate material. Any flavoring agent or active ingredient, if present in the second substrate material, may be the same or different from any flavoring agent or active agent present in the first substrate material. In some embodiments, the first substrate material and the second substrate material each comprise a flavoring agent. In certain embodiments, the flavoring agent is different in each of the first substrate material and the second substrate material.

[0183] II. Preparation of composite substrate First Substrate Material The first substrate material constituting the composite substrate can be prepared in various ways. In some embodiments, the first substrate material can be prepared using a cast sheet technique to produce the first substrate material in the form of a flat sheet form. The preparation method generally includes the steps of producing a mixture of the first substrate material, including a first filler, a first binder, water, and a first aerosol-forming material; and casting the slurry onto a support device or surface to form a wet sheet. For example, in some embodiments, the first substrate material components disclosed herein may be blended together to form a slurry, which may be cast onto a surface (e.g., a moving belt, band, or screen). For example, the slurry is cast or otherwise coated at a desired thickness onto an impermeable moving metal belt. Thus, the cast slurry may be subjected 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.

[0184] Generally, the first substrate material components disclosed herein are combined to form a mixture. The manner in which the various components (e.g., filler, binder, water, etc.) are combined may vary. For example, the filler and binder may be added to the water, or the water may be added to the filler and binder to create a slurry. In some embodiments, additional components are added, such as active ingredients, flavorings, aerosol-generating ingredients, etc. For clarity, references to "added" or "adding" throughout this application should not be construed as limiting with respect to the manner in which the various components are contacted with each other. For example, the components mentioned above may be in liquid or dry solid form and may be mixed with any remaining ingredients or simply mixed together with all other liquid or dry ingredients in a pre-treatment step prior to mixing. Any individual component of the first substrate material may also be added to any other first substrate material component, either individually or in any combination.

[0185] The specific ingredients and the ratios of the various ingredients utilized may vary and depend on the intended form and use of the first substrate material. In some embodiments, the specific ingredients and amounts of each are as disclosed herein with respect to the first substrate material embodiment. In some embodiments, the method of preparing a first substrate material in the form of a cast sheet includes combining a filler material including tobacco material, calcium carbonate, wood pulp, maltodextrin, or a combination thereof with a binder, water, and an aerosol-forming material. In some embodiments, the binder is a cellulose ether, such as carboxymethylcellulose. In some embodiments, the aerosol-forming material is glycerin. In addition to its role as an aerosol-forming material, glycerin can also act as a humectant that promotes the flexibility of the sheet. In some embodiments, the glycerin is slowly added to the calcium carbonate and mixed before combining with additional ingredients (e.g., water, binder, and milled tobacco material, wood pulp, maltodextrin, or a combination thereof). In some embodiments, the method includes the steps of mixing carboxymethylcellulose with water in a vessel to create a carboxymethylcellulose slurry; adding the carboxymethylcellulose slurry to a calcium carbonate-glycerin slurry; and mixing the carboxymethylcellulose slurry and the calcium carbonate-glycerol slurry. The remaining ingredients (e.g., tobacco material, wood pulp, maltodextrin, or combinations thereof) may be added to the slurry, either individually or as a preformed mixture of any of them, or the slurry may be added to the remaining ingredients.

[0186] The various components of the first substrate material can be contacted, combined, or mixed together using any mixing technique or device known in the art. Any mixing method that brings the first substrate material 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 methods 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.

[0187] Mixing times and speeds may be varied to suit a particular application. The various mixing steps can be at medium and / or variable speeds (e.g., about 50-500 RPM, e.g., about 75-150 RPM). The various mixing steps can last for about 5 minutes to 60 minutes, e.g., about 15 minutes to 45 minutes or about 30 minutes.

[0188] In some embodiments, casting the first substrate material mixture comprises casting the final slurry of the first substrate material mixture onto the support surface using a casting knife set at about 1-3 mm gap opening. In some embodiments, the first substrate material is used as is in the form of a wet sheet. In other embodiments, the wet sheet is solidified. In some embodiments, solidifying the wet sheet comprises drying the cast first substrate material mixture by heating.

[0189] Second Substrate Material The second substrate material that constitutes the composite substrate can be prepared in various ways. The specific components and the ratio of the various components that are utilized can vary and depend on the intended use of the second substrate material. In some embodiments, the specific components and the amount of each component are as disclosed herein for the second substrate material.

[0190] In some embodiments, the second substrate material is in the form of a sheet. In such embodiments, the components of the second substrate material are combined and processed to form a sheet as described for the first substrate material.

[0191] In some embodiments, the second substrate material is in the form of beads, spheres, rods, etc. In some embodiments, the second substrate material is in the form of beads. Generally, the beaded or rod-shaped second substrate material disclosed herein can be prepared using extrusion and spheronization techniques. By way of non-limiting example, the beaded or rod-shaped second substrate material disclosed herein can be prepared by combining the individual second substrate material components (e.g., second filler, second binder, water, etc.) to form a slurry, extruding the slurry, and spheronizing the extrudate.

[0192] In some embodiments, the method of preparing a second substrate material in beaded form comprises combining a milled tobacco material and a filler material comprising calcium carbonate with water, an aerosol-forming material, or a combination thereof. In some embodiments, the method further comprises adding a binder. In some embodiments, the binder is a cellulose ether, such as carboxymethylcellulose. In some embodiments, further ingredients are added, such as an active ingredient, a flavoring agent, or both.

[0193] Generally, the second substrate material components disclosed herein are combined to form a slurry. The manner in which the various components are combined may vary. Any of the components described may be in liquid or dry solid form and may be blended or simply mixed together with all other liquid or dry components in a pre-treatment step prior to mixing with any remaining components. Any individual component of the second substrate material may be added to any other second substrate material component, either individually or in any combination. The various components of the second substrate material may be contacted, combined, or mixed together using any mixing technique or device known in the art, as described above for the base material. Similarly, the mixing time and speed may vary.

[0194] In some embodiments, the second substrate component is granulated (agglomerized). Granulation is a process in which primary powder particles of individual components are bonded together to form large, homogenous, multiparticulate units called granules. Any suitable means for granulation can be utilized. For example, granulation can be performed under high shear, low shear, fluidized bed, rotor, or melt granulation.

[0195] After the second substrate material component is combined to form a slurry or granulate, the slurry or agglomerates are then extruded. Extrusion can be accomplished by extruding the slurry or agglomerates through a perforated screen of suitable size using an extruder, such as a screw, sieve, basket, roll and ram type extruder. Any suitable extrudate shape can be used. In some embodiments, the slurry or agglomerates are extruded into a rod shape.

[0196] The extrudate is then subjected to spheronization or spheronization to produce beads of round or oval shape. Thus, in some embodiments, the method further comprises the steps of dividing the second substrate material mixture, transferring a portion of the second substrate material mixture to an extruder to form a rod of the substrate mixture, and transferring at least a portion of the extruded rod to a spheronizer to form round beads of the second substrate material mixture. In some embodiments, the extrudate is processed in a spheronizer (e.g., a spheronizer available from Caleva Process Solutions Ltd. or LCI Corporation) at an appropriate rotation speed (e.g., 1200 RPM) for an appropriate time (e.g., 10 minutes). For example, spheronization can be performed using a spinning friction plate that performs rounding of the extrudate particles.

[0197] The beads can be optionally dried to remove at least a portion of the liquid content (e.g., water). The resulting beads can be dried in a fluidized bed dryer, apron dryer, rotary dryer, flash dryer, tray dryer, or plow mixer. The final moisture content can be about 3-20% moisture by weight on a wet basis.

[0198] After optional drying, the variously sized beads can be processed through a series of screens to obtain the desired size range. Additionally, flavorings, extracts, aerosol forming materials, etc. can also be added to the beads after drying.

[0199] Composite base material To form a composite substrate as disclosed herein, a second substrate material is applied to the first substrate material, hi some embodiments, the first substrate material and the second substrate material are in the form of sheets and are applied together in a layered configuration.

[0200] In some embodiments, the first substrate material is in the form of a sheet and the second substrate material is in the form of one or more beads that are attached to or embedded in the first substrate material. In such embodiments, the second substrate material in the form of beads is typically deposited on the surface of the first substrate material in the form of a cast sheet. The second substrate material is deposited on the surface of the first substrate material sheet using any suitable means, for example, a doser. In some embodiments, the beads are deposited by a doser by application of high temperature, causing the beads to fall onto the first substrate material sheet as it moves down a conveyor line. The amount of beads deposited may vary, for example, a single bead or multiple beads. The amount of beads present may be expressed as a percentage by weight of the composite substrate. For example, the composite substrate may include an amount of beaded material of about 10% to about 70% by weight, for example, about 10%, about 20%, about 30%, about 40%, about 50%, about 60% or about 70% by weight, based on the total weight of the composite substrate. In some embodiments, the composite substrate comprises beaded material in an amount of about 10% to about 50% or about 20% to about 40% by weight, based on the total weight of the substrate.

[0201] The beaded material may be applied to the surface of the first substrate material in a random or uniform pattern. In some embodiments, the beaded material is randomly deposited (i.e., scattered) without regard to spacing or application density. In some embodiments, the beaded material is deposited in a uniform manner such that the distribution of beads is regular with respect to spacing. For example, the beaded material may be deposited in lines or rows, in lines or rows aligned with each other, or offset from each other.

[0202] After the beaded material is deposited, the wet sheet on which the beaded material is deposited can be dried to adhere the beaded material to the base material to form a composite substrate. The wet sheet is typically dried to a desired moisture level. Drying can be achieved using a variety of techniques. For example, the wet sheet can be (i) air dried at ambient conditions, (ii) heated on a heated metal surface, (iii) subjected to contact with heated air, or (iv) heated on a heated metal surface and subjected to contact with heated air.

[0203] In some embodiments, the composite substrate can be coated or laminated before or after drying to avoid loss (e.g., shearing) of the beaded material during subsequent processing. For example, in some embodiments, the composite substrate is in a layered form, with the beaded material embedded between layers of the first substrate material. To obtain such an embodiment, a second layer of the first substrate material slurry is cast onto the first layer of the first substrate material on which the beaded material is disposed or adhered. This second layer can be applied before or after drying the first layer of the first substrate material on which the beaded material is disposed or adhered. The layered composite substrate is then dried as described above to form a layered composite substrate with the beaded material embedded therein.

[0204] In some embodiments, the method further comprises removing the composite substrate from the support surface and, optionally, winding the composite substrate onto a bobbin.

[0205] The final form of the composite substrate may vary. In some embodiments, the composite substrate is in flat sheet form, gathered sheet form, multi-layer sheet form, rolled sheet form, or strip material form. In some embodiments, the composite substrate is in flat sheet form. In some embodiments, the flat sheet form is layered, e.g., a series of overlapping layers. FIG. 3 illustrates a schematic perspective view of an aerosol-generating component according to an exemplary embodiment of the present disclosure. In particular, FIG. 3 illustrates an aerosol-generating component 104 having a substrate portion 110 that includes a series of overlapping layers 130 of substrates disclosed herein in sheet form 120. In the illustrated embodiment, the substrate sheet 120 includes a layer of a first substrate material having a plurality of beads adhered thereto, each as disclosed herein.

[0206] In some embodiments, the flat sheet form may be a bundled, rolled, crimped and / or otherwise collected layer. The flat sheet form may also be collected or wound into a rod for insertion into the substrate-containing segment (aerosol-generating component) of the aerosol delivery device.

[0207] In some embodiments, the composite substrate may be reduced in size and inserted into a substrate-containing segment of an aerosol delivery device. In some embodiments, reducing the size includes cutting the composite substrate into strips or chopping the composite substrate. Thus, in some embodiments, the method of preparing a composite substrate further includes cutting the composite substrate into a plurality of strips, which may vary in size.

[0208] In some embodiments, the composite substrate can be combined with additional materials. For example, the composite substrate can be combined with tobacco materials, including reconstituted tobacco materials ("recon" tobacco), or aerosol-generating materials, or both, each as described herein above. For example, in some embodiments, one or more aerosol-forming materials can be sprayed onto or otherwise disposed in or on the composite substrate material. Methods for loading (e.g., impregnating) aerosol-forming materials into or on substrate portions are described in U.S. Patent No. 9,974,334 to Dooly et al. and U.S. Published Patent Application No. 2015 / 0313283 to Collett et al. and U.S. Published Patent Application No. 2018 / 0279673 to Sebastian et al., the disclosures of which are incorporated herein by reference in their entirety. Additional materials (e.g., tobacco materials, non-tobacco materials, or both) can also be combined with the composite substrate in other configurations. For example, tobacco material may be combined with beaded material, non-tobacco material may be combined with cast sheets, or any permutation or combination thereof.

[0209] III. Aerosol-Generating Components and Aerosol Delivery Devices The composite substrate according to the embodiment of the present disclosure can be used in an aerosol delivery device or its aerosol-generating component.Accordingly, a further exemplary embodiment of the present disclosure relates to an aerosol delivery device comprising an aerosol-generating component 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 passage extending from the aerosol-generating component to the mouth end of the aerosol delivery device.The individual components and construction of the aerosol-generating component and the aerosol delivery device are provided herein below.

[0210] The aerosol-generating components 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 type of taste or flavor, 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 components. 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.

[0211] Although the present system is generally described herein in terms of embodiments relating to aerosol delivery devices and / or aerosol generating components, e.g., so-called "e-cigarettes" or "heat-not-burn 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.

[0212] The aerosol delivery device and / or aerosol generating components of the present disclosure may also be characterized as being a vapor product or pharmaceutical delivery article. Thus, such articles or devices may also 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.

[0213] More specific formats, configurations and arrangements of the various substrate materials, aerosol generating components and components within the aerosol delivery devices 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.

[0214] Substrates according to certain embodiments of the present disclosure can be used in the aerosol generation segment of a heated-not-burn (HNB) device, which uses 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. The components of such a system have the form of an article small enough to be considered a handheld device. That is, the use of certain exemplary aerosol delivery device components does not result in the production of smoke, in the sense that aerosols are 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.

[0215] Thus, in some embodiments, the aerosol generating components 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, component, module, member, or the like. The overall design 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 component. While other configurations are possible, in some aspects it may be desirable for the overall design, size, and / or shape of these embodiments to be similar to that of a traditional cigarette or cigar.

[0216] Substrates according to certain embodiments of the present disclosure can be used in the aerosol generating components 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 a power source (e.g., a power supply), at least one control component (e.g., a means for activating, controlling, regulating, and stopping the power for heat generation by controlling the current from the power source to other components of the article, e.g., a microprocessor, either individually or as part of a microcontroller), a heat source (e.g., an 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 component 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., cellulosic films) such that the heater traces can be powered by a power 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.

[0217] 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 design 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 separable housings that are joined together. For example, the aerosol delivery device may have a control device 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 at the other end an outer casing or shell containing a disposable portion (e.g., a disposable flavor-containing aerosol generating component) that is removably connectable thereto.

[0218] Aerosol generating components 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 1-6.

[0219] In this regard, FIG. 1 illustrates an aerosol delivery device 100 according to an exemplary embodiment of the present disclosure. The aerosol delivery device 100 can include a controller 102 and an aerosol generating component 104. In some embodiments, the aerosol generating component is configured for use with 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.

[0220] 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 metallic materials and are designed to generate heat as a result of electrical resistance associated with passing an electric current therethrough. Such resistive heating members may be positioned 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 controller 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 proximate to the engagement end of the controller 102 and may be configured to substantially surround a portion of the heated end 106 of the aerosol generating component 104, including the substrate portion 110. In this manner, the heating element can be located proximate 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 that penetrate 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 a variety of forms and in some embodiments, can directly contact and / or penetrate the substrate portion. In addition to being designed for use with a conductive heat source, as described above, the aerosol generating element disclosed herein may also be designed 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 resonant receiver can be located in the controller 102. In other embodiments, the resonant receiver, or a portion thereof, can be located in the aerosol generating component 104. For example, in some embodiments, the controller 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 generating component is in intimate contact with the resonant receiver.

[0221] In other embodiments, the resonant transmitter can include a helical coil configured to surround the periphery of the cavity that receives the aerosol generating components, particularly the substrate portion of the aerosol generating components. 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 oval 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, thus including the resonant transmitter. In various embodiments, the aerosol generating components can be received in the receiving cavity, and one or more of the aerosol generating components can function as the resonant receiver. In some embodiments, the aerosol generating components include the 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.

[0222] In various embodiments, the aerosol generating components 104 and the controller 102 may be permanently or separably aligned in operative relationship. In this regard, Figure 1 illustrates the aerosol delivery device 100 in a coupled configuration, while Figure 2 illustrates the aerosol delivery device 100 in a decoupled configuration. The aerosol generating components 104 may be coupled with the controller 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.

[0223] In various embodiments, the aerosol delivery device 100 according to exemplary embodiments of the present disclosure can have a variety of overall shapes, including, but not limited to, an overall shape that may be defined as a substantially rod-like or substantially tubular shape or a substantially cylindrical shape. In the embodiment of FIGS. 1-2, 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, the controller 102 or one or both of the aerosol generating components 104 (and / or any sub-components) can have a substantially rectangular shape, such as a substantially rectangular cubic shape (e.g., a shape similar to a USB flash drive). In other embodiments, the controller 102 or one or both of the aerosol generating components 104 (and / or any sub-components) 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-generating component 104.

[0224] 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 sufficiently close to the substrate portion such 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.

[0225] 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 power source can take various embodiments. The power 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 power source is sized to fit conveniently within the aerosol delivery device so that the aerosol delivery device is easily handled. Examples of useful power 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 power source is lightweight enough that the desired smoking experience is not compromised. Some examples of possible power sources are described in U.S. Pat. No. 9,484,155 to Peckerar et al. and U.S. Patent Application Publication No. 2017 / 0112191 to Sur et al., the disclosures of which are each incorporated by reference in their entirety.

[0226] In certain embodiments, one or both of the controller 102 and the aerosol generating components 104 can be referred to as disposable or reusable. For example, the controller 102 can have a replaceable or rechargeable battery, a solid-state battery, a thin-film solid-state battery, a rechargeable supercapacitor, or the like, 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. Additionally, in some embodiments, the aerosol generating component 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.

[0227] In a further embodiment, the power source can also include a capacitor. The capacitor can discharge faster than the battery and can 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 the heat source. For example, a supercapacitor, such as an electric double layer capacitor (EDLC), can be used separately from the battery or in combination with the battery. When used alone, the supercapacitor can be recharged before each use of the article. Thus, the device can also include a charger component that can be attached to the smoking article between each use to replenish the supercapacitor.

[0228] 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 the 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 the Model 163PC01D36 silicon sensor, manufactured by MicroSwitch division of Honeywell, Inc., Freeport, Ill. Representative flow sensors, current regulators and other current control components, including various microcontrollers, sensors and switches for aerosol delivery devices are described in U.S. Patent No. 4,735,217 to Gerth et al., U.S. Patent Nos. 4,922,901, 4,947,874 and 4,947,875, all to Brooks et al., U.S. Patent No. 5,372,148 to McCafferty et al., U.S. Patent No. 6,040,560 to Fleischhauer et al., U.S. Patent No. 7,040,314 to Nguyen et al., and U.S. Patent No. 8,205,622 to Pan, all of which are incorporated 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 by reference in its entirety.

[0229] 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.

[0230] 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 the mouthpiece. U.S. Patent No. 5,967,148 to Harris et al. discloses a receptacle in a smoking device that includes an identifier that detects non-uniformity in 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 of 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 in a smoking device. U.S. Patent No. 8,402,976 to Fernando et al. discloses a 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.

[0231] 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, but are not limited to, 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. 7,896 to Hamano, each of which is incorporated by reference in its entirety. No. 6,772,756 to Shayan; U.S. Patents 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. Patents Nos. 8,915,254 and 8,925,555 to Monsees et al.; U.S. Patent No. 9,220 to DePiano et al. ,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. Additionally, Worm et al., U.S. Patent Application Publication No. 2017 / 0099877, discloses capsules that may be included in an aerosol delivery device and fob configurations for the aerosol delivery device, 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.

[0232] 2, in the embodiment shown, the aerosol-generating component 104 includes a heated end 106 (designed 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 that includes an aerosol-forming material, each as disclosed herein. In various embodiments, the aerosol-generating component 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 component 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 generating component 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.

[0233] 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 component 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 that desorbs 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.

[0234] In some embodiments, the aerosol generating component 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 components as illustrated in the attached figures) may include a body of substantially tubular shape 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 define an interior space. Various embodiments of aerosol generating components (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.

[0235] Although some of the figures described herein depict the controller and the aerosol generating components in operative relationship, it is understood that the controller and the aerosol generating components can exist as separate devices, and thus, any discussion provided elsewhere herein relating to combined components should also be understood to apply to the controller and the aerosol generating components as individual and separate components.

[0236] 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 components. 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 components and one or more charging components and / or one or more batteries. In further embodiments, the kit may include multiple aerosol generating components. The kit may further include multiple aerosol generating components and one or more batteries and / or one or more charging components. In the above embodiments, the aerosol generating components or the 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.

[0237] Figure 3 illustrates a schematic perspective view of an aerosol-generating component according to an exemplary embodiment of the present disclosure. In particular, Figure 3 illustrates an aerosol-generating component 104 having a substrate portion 110 that includes a series of overlapping layers 130 of the substrates disclosed herein in sheet form 120. 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.

[0238] FIG. 4 illustrates a schematic cross-sectional view of a substrate portion of an aerosol-generating component according to an exemplary embodiment of the present disclosure. In particular, FIG. 4 illustrates a 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 around its outer surface by a first cover layer 132. In various embodiments, the composition of the first cover layer 132 may vary, but in the embodiment shown, the first cover layer 132 includes a combination of a fibrous material, an aerosol-forming material, and a binder material. See the discussion herein regarding possible aerosol-forming and binder materials. In various embodiments, the first cover layer 132 can be constructed via a casting process, such as the method described in U.S. Pat. No. 5,697,385 to Seymour et al., the disclosure of which is incorporated herein by reference in its entirety. 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.

[0239] In various embodiments, other components may be present between the substrate portion 110 and the mouth end 108 of the aerosol-generating component 104. For example, in some embodiments, one or any combination of the following may be disposed between the substrate portion 110 and the mouth end 108 of the aerosol-generating component 104: an air gap; a hollow tube structure; a phase change material for cooling air; a flavor release medium; ion exchange fibers capable of selective chemical adsorption; aerogel particles as a filter medium; and other suitable materials. Some examples of possible phase change materials include, but are not limited to, salts such as AgNO3, AlCl3, TaCl3, InCl3, SnCl2, AlI3, and TiI4; metals and metal alloys such as selenium, tin, indium, tin-zinc, indium-zinc, or indium-bismuth; and organic compounds such as D-mannitol, succinic acid, p-nitrobenzoic acid, hydroquinone, and adipic acid. Other examples are described in US Pat. No. 8,430,106 to Potter et al., which is incorporated herein by reference in its entirety.

[0240] FIG 5 illustrates a perspective view of an aerosol-generating component according to another exemplary embodiment of the present disclosure, and FIG 6 illustrates a perspective view of the aerosol-generating component of FIG 5 with the outer packaging removed. In particular, FIG 5 illustrates the aerosol-generating component 200 including the outer packaging 202, and FIG 6 illustrates the aerosol-generating component 200 with the outer packaging 202 removed to reveal other components of the aerosol-generating component 200. In the embodiment shown, the aerosol-generating component 200 of the illustrated embodiment includes a heat source 204, a substrate portion 210, an intermediate component 208, and a filter 212. In the embodiment shown, the intermediate component 208 and the filter 212 together include a mouthpiece 214.

[0241] In various embodiments, the heat source 204 may be designed 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 of greater than about 60 percent, typically greater than about 70 percent, often greater than about 80 percent, and frequently greater than about 90 percent, typically on a dry weight basis.

[0242] In some cases, the heat source 204 can incorporate elements other than combustible carbonaceous materials (e.g., tobacco components, such as powdered tobacco or tobacco extracts; flavorings; salts, such as sodium chloride, potassium chloride, and sodium carbonate; thermally stable graphite fibers; iron oxide powder; glass filaments; powdered calcium carbonate; 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, as described hereinabove). 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 designs described in U.S. Patent No. 5,551,451 to Riggs et al. and U.S. Patent No. 7,836,897 to Borschke et al., which are incorporated 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 component. In various embodiments, the heat transfer component can be proximate to the heat source, and in some embodiments, the heat transfer component can be located within or within the heat source. Some examples of heat transfer components are described in U.S. Patent Application Publication No. 2019 / 0281891 by Hejazi et al., which is incorporated by reference in its entirety.

[0243] 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.

[0244] 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.

[0245] 5 and 6, 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 designed 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 designed 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.

[0246] In some embodiments, in addition to the outer wrapping 202, the aerosol delivery device can also include a liner configured to circumscribe at least a portion of the substrate portion 210 and the heat source 204. In other embodiments, the liner can circumscribe only a portion of the length of the substrate portion 210, while in some embodiments, the liner can circumscribe substantially 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 materials 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, in some aspects, can advantageously provide a way to engage two or more separate components of the aerosol-generating components 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.

[0247] As shown in FIG. 5, the outer wrapping material 202 (and, optionally, the liner and substrate portion 210) may also include one or more apertures formed therethrough that allow for the entry of air when drawing on the mouthpiece 214. In various embodiments, the size and number of these apertures may vary based on the requirements of a particular design. In the embodiment shown, a plurality of apertures 220 are located proximate the end of the substrate portion 210 closest to the heat source 204, and a plurality of separate cooling apertures 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 apertures 220 include a plurality of apertures substantially uniformly disposed about the outer surface of the aerosol generating component 200, and the apertures 221 also include a plurality of apertures substantially uniformly disposed about the outer surface of the aerosol generating component 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.

[0248] Referring again to FIG. 6, the aerosol-generating component 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 component 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 component 200 and to provide cooling for 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 a 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).

[0249] 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, disposed radially and / or longitudinally 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 component 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 greater 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.

[0250] 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).

[0251] 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, elements 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 component 200, including the filter 212, to the mouth of the user. In various implementations, the mouthpiece 214 (e.g., the intermediate component 208 and / or the filter 212) is designed to receive the generated aerosol therethrough in response to a draw applied by the 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.

[0252] Although the aerosol delivery device and / or aerosol generating components 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 components by a consumer falls within the same scope. The above description of the use of the aerosol delivery device and / or aerosol generating components 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 articles of the present disclosure, and is provided to comply with all necessary requirements of the disclosure herein.

[0253] 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

[0254] 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.

[0255] Example 1. Cast Sheet Base Material Embodiment - Milled Tobacco An example of an embodiment of the cast sheet base material of the present disclosure was prepared according to the formula provided in Table 1. The actual ingredients and percentages may vary depending on the desired properties of the final product.

[0256] A slurry was prepared by mixing sufficient water and carboxymethylcellulose (CMC) in a high shear mixer until the CMC was fully hydrated to obtain a 2-2.5% (w / v) solution. Glycerin was added to the slurry, followed by mixing. Tobacco and calcium carbonate were subsequently added and mixed to obtain the final slurry. The slurry was then cast onto a 22 inch (56 cm) wide stainless steel conveyor belt by decanting it from the headbox through (using) a casting or suction knife with an opening of 1-3 mm by 22 inches (56 cm) wide. The conveyor belt passed through a forced air oven with a drying zone set at 100-200°C, resulting in a cast sheet with a final moisture of 8-12%.

[0257] [Table 1]

[0258] Example 2. Cast Sheet Base Material Embodiment - Milled Tobacco Another example of an embodiment of the cast sheet base material of the present disclosure was prepared according to the formula provided in Table 2. The actual ingredients and percentages may vary depending on the desired properties of the final product.

[0259] A slurry was prepared and cast onto a conveyor belt as described in Example 1 above, except that no calcium carbonate was used in the formulation.

[0260] [Table 2]

[0261] Example 3. Cast Sheet Base Material Embodiments - Milled Tobacco and Wood Pulp Another example of an embodiment of the cast sheet base material of the present disclosure was prepared according to the formula provided in Table 3 using the general procedures of Examples 1 and 2, except that the wood pulp solution was added to and mixed with the hydrated CMC slurry prior to the addition of tobacco and calcium carbonate. The actual ingredients and percentages may vary depending on the desired properties of the final product.

[0262] [Table 3]

[0263] Example 4. Cast Sheet Base Material Embodiments - Milled Tobacco and Wood Pulp Using the general procedures of Examples 1, 2, and 3, except that calcium carbonate was omitted from this formulation, another example of an embodiment of the cast sheet base material of the present disclosure was prepared according to the formula provided in Table 4. The actual ingredients and percentages may vary depending on the desired properties of the final product.

[0264] [Table 4]

[0265] Example 5. Cast Sheet Base Material Embodiments - Wood Pulp and Maltodextrin Using the general procedures of Examples 1-4, except that maltodextrin was used instead of tobacco, another example of an embodiment of the cast sheet base material of the present disclosure was prepared according to the formula provided in Table 5. The actual ingredients and percentages may vary depending on the desired properties of the final product.

[0266] [Table 5]

[0267] Example 6. Beaded Material Embodiments An example of an embodiment of the beaded material of the present disclosure was prepared according to the formula provided in Table 6. Milled tobacco and calcium carbonate were weighed and transferred to a model FM 130 D Littleford precision plow mixer. A premixed flavoring solution (containing 2.3% flavoring, 50% glycerin, 45% water, and 2.3% carboxymethylcellulose) was added and the contents were mixed at 100 rpm for 10 minutes. After mixing, the Littleford contents were divided and transferred to a single screw extruder (model MG55, Fuji Paudal). The mass was extruded through a 1.5 mm dome die, resulting in strand-shaped microfibrillar rods. The rods were then transferred to a model QJ-230T-2 Fuji Paudal Co. Ltd. laboratory marumerizer. The rotating bowl of the marumerizer was used to reform the rods into circular beads. The beads were then transferred to a model Flo-Coater Vector Corporation fluidized bed agglomerator and finally dried with heated air at 60-70°C to 6% (±3%) moisture.

[0268] [Table 6]

[0269] Example 7. Beaded Material Embodiments Another example of an embodiment of the beaded material of the present disclosure was prepared according to the formula provided in Table 7. Milled tobacco and calcium carbonate were weighed and transferred to a Model FM 130 D Littleford precision plow mixer. Water and glycerin were added. The contents were mixed at 100 rpm for 10 minutes. The mixer was stopped, a pre-made slurry of carboxymethylcellulose was added, and the contents were mixed at 100 rpm for another 20 minutes. A pitched fork propeller was used to prepare a pre-made slurry by hydrating the carboxymethylcellulose with water in a container. This was done for 30 minutes. After mixing for 20 minutes, the Littleford contents were divided and transferred to a single screw extruder. The mass was extruded through a 1.5 mm dome die, resulting in the shape of a rod. The rod was then transferred to a Model QJ-230T-2 Fuji Paudal Co. Ltd. laboratory marumerizer. The rotating bowl of the marumerizer was used to reform the rod into a circular bead. The beads were then transferred to a model Flo-Coater Vector Corporation fluidized bed agglomerator and finally dried with 60-70°C heated air to 6% (±3%) moisture.

[0270] [Table 7]

[0271] Examples 8A-8C. Embodiments of a Cast Sheet Base Material and a Substrate with Adhered Beads Three examples of embodiments of the substrate of the present disclosure having cast sheet base material and beads attached thereto were prepared by depositing beads prepared according to Example 7 onto the wet cast sheets of Examples 3, 4, and 5, respectively. A doser was used to deposit the bead material onto the wet cast sheets. The beads constituted approximately 30% of the total substrate wet weight. The cast sheets of attached beads were then dried into a flat sheet form by conveying the film through a 200 foot (61 meter) convection tunnel dryer containing multiple heating zones (e.g., in the range of 80-100°C). Photographs of cast sheets with attached beads corresponding to each of Examples 8A, 8B, and 8C, respectively, are provided in Figure 7 (cast sheet without tobacco), Figure 8 (cast sheet with tobacco and calcium carbonate), and Figure 9 (cast sheet with tobacco and without calcium carbonate).

Claims

1. 1. A composite substrate configured for use in an aerosol delivery device, comprising: a first substrate material comprising a first filler material, a binder, and an aerosol-forming material; and a second substrate material attached to the first substrate material, the second substrate material comprising a second filler material, a second binder, and a second aerosol-forming material; A composite substrate comprising:

2. 10. The composite substrate of claim 1, wherein the second substrate material is in the form of one or more beads, spheres, or rods that are adhered to or embedded within the first substrate material.

3. The composite substrate of claim 1 , wherein the first substrate material is in the form of a sheet.

4. The composite substrate of claim 1 , wherein the first substrate material is in the form of a strip or particulate material.

5. 10. The composite substrate of claim 1, wherein both the first substrate material and the second substrate material are in the form of sheets attached together in a layered configuration.

6. The composite substrate of claim 1 , wherein the first substrate material and the second substrate material have one or more of different compositions, different densities, and different outer shapes.

7. 7. The composite substrate of claim 6, wherein the density of the second substrate material is at least 10% greater than the density of the first substrate material.

8. 10. The composite substrate of claim 1, wherein the first substrate material comprises at least 50% by weight of the first filler, based on the total dry weight of the first substrate material.

9. 10. The composite substrate of claim 1, wherein the first substrate material comprises from 50% to 75% by weight of the first filler, based on the total dry weight of the first substrate material.

10. 10. The composite substrate of claim 1, wherein the first filler and the second filler are independently selected from the group consisting of tobacco material, plant material, wood pulp, natural or modified starch, maltodextrin, glucose, calcium carbonate, sugar alcohols, microcrystalline cellulose, and combinations thereof.

11. 10. The composite substrate of claim 1, wherein the first filler and the second filler are independently selected from the group consisting of tobacco material, wood pulp, maltodextrin, calcium carbonate, and combinations thereof.

12. 10. The composite substrate of claim 1, wherein the first filler and the second filler are independently selected from the group consisting of wood pulp, maltodextrin, calcium carbonate, and combinations thereof.

13. 2. The composite substrate of claim 1, wherein the first binder and the second binder comprise a cellulose ether independently selected from the group consisting of methyl cellulose, hydroxypropyl cellulose (HPC), hydroxypropyl methyl cellulose (HPMC), hydroxyethyl cellulose, carboxymethyl cellulose (CMC), and combinations thereof.

14. The composite substrate of claim 1 , wherein the first binder and the second binder comprise CMC.

15. 2. The composite substrate of claim 1, wherein the first aerosol-forming material and the second aerosol-forming material are independently selected from the group consisting of water, polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, cannabinoids, terpenes, sugar alcohols, and combinations thereof.

16. The composite substrate of claim 1 , wherein the first aerosol-forming material and the second aerosol-forming material each comprise a polyhydric alcohol.

17. 17. The composite substrate of claim 16, wherein the polyhydric alcohol is selected from the group consisting of glycerin, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, triacetin, and combinations thereof.

18. a first substrate material comprising: tobacco material in an amount of 0% to 70% by weight, based on the total wet weight of the first substrate material; wood pulp in an amount of 0% to 10% by weight, based on the total wet weight of the first substrate material; calcium carbonate in an amount of 0% to 30% by weight, based on the total wet weight of the first substrate material; maltodextrin in an amount of 0% to 40% by weight, based on the total wet weight of the first substrate material; glycerin in an amount of 10% to 20% by weight, based on the total wet weight of the first substrate material; Carboxymethylcellulose in an amount of 5% to 15% by weight, based on the total wet weight of the first substrate material; and Water in an amount of up to 30% by weight based on the total wet weight of the first substrate material. The composite substrate of claim 1 , comprising:

19. 10. The composite substrate of claim 1, wherein the first substrate material further comprises a flavoring agent, an active ingredient, a tobacco extract, or a combination thereof.

20. 20. The composite substrate of claim 19, wherein the active ingredient comprises a nicotine ingredient.

21. 3. The composite substrate of claim 2, wherein the beads, spheres, or rods comprise at least 50% by weight of the second filler, based on the total dry weight of the beads.

22. 3. The composite substrate of claim 2, wherein the beads, spheres, or rods comprise 50% to 65% by weight of the second filler, based on the total dry weight of the beads.

23. 3. The composite substrate of claim 2, wherein the second filler material comprises tobacco material, plant material, calcium carbonate, or a combination thereof.

24. 3. The composite substrate of claim 2, wherein the second filler material is selected from the group consisting of tobacco material, calcium carbonate, and combinations thereof.

25. 3. The composite substrate of claim 2, wherein the second binder is selected from the group consisting of methyl cellulose, hydroxypropyl cellulose (HPC), hydroxypropyl methyl cellulose (HPMC), hydroxyethyl cellulose, carboxymethyl cellulose (CMC), and combinations thereof.

26. 26. The composite substrate of claim 25, wherein the second binder is CMC.

27. Beads, spheres or rods tobacco material in an amount of 20% to 40% by weight, based on the total dry weight of the bead, sphere, or rod; calcium carbonate in an amount of 20% to 40% by weight, based on the total dry weight of the beads, spheres or rods; Glycerin in an amount of 0% to 20% by weight based on the total dry weight of the bead, sphere, or rod; and Carboxymethylcellulose in an amount of 0% to 2% by weight based on the total dry weight of the beads, spheres or rods The composite substrate of claim 2 comprising:

28. 3. The composite substrate of claim 2, wherein the beads, spheres, or rods further comprise a flavoring agent, an active ingredient, or a combination thereof.

29. 3. The composite substrate of claim 2, wherein the second aerosol-forming material is selected from the group consisting of water, polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, cannabinoids, terpenes, sugar alcohols, and any combination thereof.

30. 30. The composite substrate of claim 29, wherein the polyhydric alcohol is selected from the group consisting of glycerol, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, triacetin, and combinations thereof.

31. 3. The composite substrate of claim 2, comprising 10% to 50% by weight of beads, spheres, or rods, based on the total weight of the composite substrate.

32. 3. The composite substrate of claim 2, wherein the beads, spheres, or rods have a diameter in the range of 0.1 mm to 5 mm.

33. 3. The composite substrate of claim 2, wherein the beads, spheres, or rods are adhered to the surface of the first substrate material in a randomly arranged pattern.

34. 3. The composite substrate of claim 2, wherein the beads, spheres, or rods are adhered to the surface of the first substrate material in a uniformly spaced pattern.

35. The composite substrate of claim 1 , wherein the substrate is substantially free of wood fibers.

36. 10. The composite substrate of claim 1, wherein the substrate is substantially free of tobacco material.

37. 10. The composite substrate of claim 1, which is in the form of a flat sheet, a gathered sheet, a multi-layer sheet, a rolled sheet, or a strip.

38. 10. The composite substrate of claim 1 in strip form further blended with tobacco material.

39. The composite substrate according to any one of claims 1 to 38, a heat source configured to heat the composite substrate to form an aerosol; and an aerosol pathway extending from the composite substrate to the mouth end of the aerosol delivery device; 1. An aerosol delivery device comprising:

40. 40. The aerosol delivery device of claim 39, wherein the heat source comprises an electric heating element or a combustible ignition source.

41. 41. The aerosol delivery device of claim 40, wherein the heat source is a combustible ignition source comprising a carbon-based material.

42. 41. The aerosol delivery device of claim 40, wherein the heat source is an electric heating element.

43. 43. The aerosol delivery device of claim 42, further comprising a power source electronically connected to the heating element.

44. 44. The aerosol delivery device of claim 43, further comprising a controller configured to control the power delivered by the power source to the heating element.

45. 1. A method of making a composite substrate configured for use in an aerosol delivery device, comprising: (a) preparing a slurry including a first filler material, a first binder, and a first aerosol-forming material; (b) casting the slurry onto a support device to form a first substrate material in the form of a wet sheet; (c) preparing a second substrate material comprising a second filler material, a second binder, and a second aerosol-forming material, wherein the second substrate material is in beaded form; (d) depositing a second substrate material onto the surface of the first substrate material; and (e) drying the first substrate material having deposited thereon the second substrate material in beaded form to form a composite substrate, wherein the second substrate material in beaded form is adhered to a surface of the first substrate material substrate. A method comprising:

46. The slurry is tobacco or plant material in an amount of 0% to 70% by weight, based on the total wet weight of the slurry; wood pulp in an amount of 0% to 10% by weight, based on the total wet weight of the slurry; an additional first filler in an amount of 0% to 70% by weight based on the total wet weight of the slurry, the additional first filler comprising native or modified starch, maltodextrin, glucose, calcium carbonate, sugar alcohol, microcrystalline cellulose, or a combination thereof; a first aerosol-forming material in an amount of 10% to 20% by weight, based on the total wet weight of the slurry; a cellulose ether in an amount of 5% to 15% by weight based on the total wet weight of the slurry, and Water in an amount of up to 30% by weight based on the total wet weight of the slurry 46. ​​The method of claim 45, comprising:

47. a second substrate material in beaded form, tobacco or plant material in an amount of 20% to 40% by weight, based on the total dry weight of the second substrate material; an additional second filler in an amount of 20% to 40% by weight, based on the total dry weight of the second substrate material; a second aerosol-forming agent in an amount of 0% to 20% by weight, based on the total dry weight of the second substrate material; and cellulose ether in an amount of 0% to 2% by weight, based on the total dry weight of the second substrate material; 47. The method of claim 46, comprising:

48. (f) casting a layer of the slurry onto the composite substrate of (e) to form a wet layered composite substrate; and (g) drying the wet layered composite substrate to form a layered composite substrate having embedded therein a second substrate material in beaded form; 47. The method of claim 46, further comprising:

Images