Substrate with multiple aerosol-forming materials for an aerosol delivery device - Patent Application 20070122997

Abstract

A substrate is provided that includes a plurality of aerosol-forming agents to allow for controlled release of an aerosol over time as the substrate is heated. The present invention provides an aerosol-generating member comprising a substrate impregnated with two or more aerosol-forming materials, including a first aerosol-forming material and a second aerosol-forming material, wherein the first aerosol-forming material and the second aerosol-forming material have different boiling points, different vapor pressures, or both. The disclosed aerosol-generating member can be utilized in aerosol delivery devices, such as non-combustion heated (HNB) or electrically heated aerosol delivery devices.

Description

[Technical Field]

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

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

[0003] A key focus for improvements or replacements to smoking articles has typically been to provide the sensations associated with cigarette, cigar, or pipe smoking without delivering significant amounts of incomplete combustion and pyrolysis products. To this end, numerous smoking products, flavor generators, and medicinal inhalers have been proposed that utilize electrical energy to vaporize or heat volatile materials or attempt to provide the sensations of cigarette, cigar, or pipe smoking without significantly burning tobacco. See, for example, the various alternative smoking articles, aerosol delivery devices, and heat sources described in the background art of U.S. Pat. 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.

[0004] 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 have suffered from inconsistent release of flavor or other inhalation materials and inadequate loading of aerosol-forming materials into the substrate.Therefore, it is desirable to provide a smoking article that has advantageous performance characteristics without burning the substrate material and can provide the sensation of smoking a cigarette, cigar, or pipe.

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

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

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

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

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

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

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

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

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

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

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

[0016] In some embodiments, the substrate further comprises one or more binders. In some embodiments, the one or more binders are selected from alginate, cellulose derivatives, starch, gum, dextran, carrageenan, calcium carbonate, or a combination thereof. In some embodiments, the substrate comprises one or more of calcium carbonate, alginate, one or more cellulose derivatives, starch, wood pulp, or tobacco-derived fiber. In some embodiments, the two or more aerosol-forming materials are present in a weight ratio of about 3:1 to about 1:3. In some embodiments, the two or more aerosol-forming materials are glycerol and propylene glycol.

[0017] In some embodiments, the substrate comprises about 0 to about 60% by weight calcium carbonate, about 0 to about 10% by weight alginate, about 0 to about 5% by weight one or more cellulose derivatives, about 0 to about 30% by weight starch, about 0 to about 5% by weight wood pulp, and about 0 to about 80% by weight tobacco-derived fiber, and the substrate is impregnated with two or more aerosol-forming materials at a loading of about 15 to about 55% by weight, based on the total weight of the impregnated substrate.

[0018] In some embodiments, the substrate comprises about 0 to about 5% by weight calcium carbonate, about 1% to about 5% by weight wood pulp, and about 70 to about 80% by weight tobacco-derived fiber, and the substrate is impregnated with two or more aerosol-forming materials at a loading of about 15 to about 25% by weight, based on the total weight of the impregnated substrate.

[0019] In some embodiments, the substrate comprises about 45 to about 60 wt. % calcium carbonate, about 0 to about 10 wt. % alginate, about 0 to about 5 wt. % one or more cellulose derivatives, about 0 to about 15 wt. % starch, about 0 to about 5 wt. % wood pulp, and about 0 to about 40 wt. % tobacco-derived fiber, and the substrate is impregnated with two or more aerosol-forming materials at a loading of about 15 to about 25 wt. % based on the total weight of the impregnated substrate.

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

[0021] In some embodiments, the substrate comprises about 5 to about 15 wt. % calcium carbonate, about 1 to about 5 wt. % one or more cellulose derivatives, about 20 to about 40 wt. % starch, and about 20 to about 40 wt. % tobacco-derived fiber, and the substrate is impregnated with two or more aerosol-forming materials at a loading of about 15 to about 25 wt. % based on the total weight of the impregnated substrate.

[0022] In another aspect, there is provided an aerosol delivery device comprising: an aerosol-generating member as described herein; a heat source configured to heat an aerosol-forming material impregnated in a substrate portion to form an aerosol; and an aerosol pathway extending from the aerosol-generating member to a mouth end of the aerosol delivery device.

[0023] In some embodiments, the heat source comprises either an electric heating element or a combustible ignition source. In some embodiments, the heat source is a combustible ignition source comprising a carbon-based material. In some embodiments, the heat source is an electric heating element. In some embodiments, the aerosol delivery device further comprises a power source electrically connected to the heating element. In some embodiments, the aerosol delivery device further comprises a controller configured to control power transmitted by the power source to the heating element.

[0024] The present disclosure includes, but is not limited to, the following embodiments.

[0025] Embodiment 1: An aerosol-generating member comprising a substrate impregnated with two or more aerosol-forming materials, including a first aerosol-forming material and a second aerosol-forming material, wherein the first aerosol-forming material and the second aerosol-forming material each have a different boiling point, a different vapor pressure, or both.

[0026] Embodiment 2: The aerosol-generating member of embodiment 1, wherein the first aerosol-forming material and the second aerosol-forming material are independently selected from the group consisting of water, polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, triacetin, and sugar alcohols.

[0027] Embodiment 3: The aerosol-generating member of embodiment 1 or 2, wherein the two or more aerosol-forming materials are present in a weight ratio of the first aerosol-forming material to the second aerosol-forming material of about 3:1 to about 1:3.

[0028] Embodiment 4: The aerosol-generating member according to any one of embodiments 1 to 3, wherein at least one of the first aerosol-forming material and the second aerosol-forming material is a polyhydric alcohol.

[0029] Embodiment 5: The aerosol-generating member according to any one of embodiments 1 to 4, wherein both the first aerosol-forming material and the second aerosol-forming material are polyhydric alcohols.

[0030] Embodiment 6: The aerosol-generating member according to any one of embodiments 1 to 5, wherein the polyhydric alcohol is selected from the group consisting of glycerol, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, and combinations thereof.

[0031] Embodiment 7: The aerosol-generating member according to any one of embodiments 1 to 6, wherein the polyhydric alcohol is glycerol and propylene glycol.

[0032] Embodiment 8: An aerosol-generating member according to any one of embodiments 1 to 7, wherein the glycerol and propylene glycol are present in a weight ratio of about 3:1 to about 1:3.

[0033] Embodiment 9: An aerosol-generating member according to any one of embodiments 1 to 8, wherein the glycerol and propylene glycol are present in a weight ratio of about 1:1.

[0034] Embodiment 10: An aerosol-generating member according to any one of embodiments 1 to 9, wherein the substrate is further impregnated with at least one additional aerosol-forming agent.

[0035] Embodiment 11: An aerosol-generating member described in any one of embodiments 1 to 10, wherein the at least one additional aerosol-forming agent is selected from the group consisting of water, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, triacetin, sugar alcohols, cannabinoids, terpenes, and combinations thereof.

[0036] Embodiment 12: An aerosol-generating member according to any one of embodiments 1 to 11, wherein the substrate is further impregnated with a flavoring agent, an active ingredient, or a combination thereof.

[0037] Embodiment 13: An aerosol-generating member according to any one of embodiments 1 to 12, wherein the active ingredient comprises a non-tobacco botanical, a tobacco component, a nicotine component, or a combination thereof.

[0038] Embodiment 14: The aerosol-generating member according to any one of embodiments 1 to 13, wherein the active ingredient comprises a nicotine component.

[0039] Embodiment 15: An aerosol-generating member according to any one of embodiments 1 to 14, wherein the substrate is impregnated with two or more aerosol-forming materials at a loading of about 15 to about 55 wt %, based on the total weight of the impregnated substrate.

[0040] Embodiment 16: An aerosol-generating member according to any one of embodiments 1 to 15, wherein the substrate is in particulate form, shredded form, film form, paper process sheet form, cast sheet form, bead form, granular rod form or extrudate form.

[0041] Embodiment 17: The aerosol-generating member of any one of embodiments 1 to 16, wherein the substrate is formed in a substantially cylindrical shape.

[0042] Embodiment 18: The aerosol-generating member of any one of embodiments 1 to 17, wherein the substrate comprises tobacco-derived fibers, wood-derived fibers, or a combination thereof.

[0043] Embodiment 19: An aerosol-generating member according to any one of embodiments 1 to 18, wherein the substrate further comprises one or more binders.

[0044] Embodiment 20: An aerosol-generating member described in any one of embodiments 1 to 19, wherein the one or more binders are selected from alginates, cellulose derivatives, starches, gums, dextran, carrageenans, calcium carbonate, or combinations thereof.

[0045] Embodiment 21: An aerosol-generating member according to any one of embodiments 1 to 20, wherein the substrate comprises one or more of calcium carbonate, alginate, one or more cellulose derivatives, starch, wood pulp, or tobacco-derived fibers.

[0046] Embodiment 22: An aerosol-generating member according to any one of embodiments 1 to 21, wherein the two or more aerosol-forming materials are present in a weight ratio of the first aerosol-forming material to the second aerosol-forming material of about 3:1 to about 1:3.

[0047] Embodiment 23: The aerosol-generating member of any one of embodiments 1 to 22, wherein the two or more aerosol-forming materials are glycerol and propylene glycol.

[0048] Embodiment 24: An aerosol-generating member according to any one of embodiments 1 to 23, wherein the substrate comprises about 0 to about 5% by weight of calcium carbonate, about 1 to about 5% by weight of wood pulp, and about 70 to about 80% by weight of tobacco-derived fiber, and the substrate is impregnated with two or more aerosol-forming materials at a loading of about 15 to about 25% by weight, based on the total weight of the impregnated substrate.

[0049] Embodiment 25: An aerosol-generating member according to any one of embodiments 1 to 24, wherein the substrate comprises about 45 to about 60 wt. % calcium carbonate, about 0 to about 10 wt. % alginate, about 0 to about 5 wt. % one or more cellulose derivatives, about 0 to about 15 wt. % starch, about 0 to about 5 wt. % wood pulp, and about 0 to about 40 wt. % tobacco-derived fiber, and the substrate is impregnated with two or more aerosol-forming materials at a loading of about 15 to about 25 wt. % based on the total weight of the impregnated substrate.

[0050] Embodiment 26: An aerosol-generating member according to any one of embodiments 1 to 25, wherein the substrate comprises about 40 to about 60 wt. % calcium carbonate, about 0 to about 10 wt. % alginate, about 0 to about 5 wt. % one or more cellulose derivatives, about 0 to about 15 wt. % starch, about 0 to about 5 wt. % wood pulp, and about 0 to about 40 wt. % tobacco-derived fiber, and the substrate is impregnated with two or more aerosol-forming materials at a loading of about 15 to about 25 wt. % based on the total weight of the impregnated substrate.

[0051] Embodiment 27: An aerosol-generating member according to any one of embodiments 1 to 26, wherein the substrate comprises about 5 to about 15% by weight of calcium carbonate, about 1 to about 5% by weight of one or more cellulose derivatives, about 20 to about 40% by weight of starch, and about 20 to about 40% by weight of tobacco-derived fiber, and the substrate is impregnated with two or more aerosol-forming materials at a loading of about 15 to about 25% by weight, based on the total weight of the impregnated substrate.

[0052] Embodiment 28: An aerosol delivery device comprising an aerosol-generating member according to any one of embodiments 1 to 27, a heat source configured to heat the impregnated substrate to form an aerosol, and an aerosol pathway extending from the aerosol-generating member to the mouth end of the aerosol delivery device.

[0053] Embodiment 29: The aerosol delivery device of embodiment 28, wherein the heat source comprises either an electric heating element or a combustible ignition source.

[0054] Embodiment 30: An aerosol delivery device described in any one of embodiments 28 and 29, wherein the heat source is a combustible ignition source comprising a carbon-based material.

[0055] Embodiment 31: An aerosol delivery device described in any one of embodiments 28 to 30, wherein the heat source is an electric heating element.

[0056] Embodiment 32: An aerosol delivery device described in any one of embodiments 28 to 31, further comprising a power source electrically connected to the heating element.

[0057] Embodiment 33: An aerosol delivery device described in any one of embodiments 28 to 32, further comprising a controller configured to control the power transmitted by the power source to the heating element.

[0058] These and other features, aspects, and advantages of the present disclosure will become apparent from the following detailed description read in conjunction with the accompanying drawings, which are briefly described below. The present invention includes any combination of two, three, four, or more of the above-described embodiments, and any combination of any two, three, four, or more features or elements described in this disclosure, whether or not such features or elements are explicitly combined in the description of a particular embodiment herein. The present disclosure is intended to be read holistically, and unless the context clearly dictates otherwise, any separable features or elements of the disclosed invention should be construed as combinable as intended in any of its various aspects and embodiments.

[0059] Having thus described aspects of the present disclosure in the foregoing general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and which are merely illustrative and should not be construed as limiting the disclosure. [Brief explanation of the drawings]

[0060] [Figure 1]1 shows a perspective view of an aerosol delivery device including a regulator and an aerosol generation member, the generator member and regulator being coupled to one another according to an exemplary embodiment of the present disclosure. [Figure 2] 2 shows a perspective view of the aerosol delivery device of FIG. 1, in which the aerosol generating member and the control body are separated according to an exemplary embodiment of the present disclosure. [Figure 3] 1 shows a schematic diagram of an aerosol-generating member according to an exemplary embodiment of the present disclosure. [Figure 4] 1 shows a schematic cross-sectional view of a substrate portion of an aerosol-generating member according to an exemplary embodiment of the present disclosure. [Figure 5] 1 shows a perspective view of an aerosol-generating member according to an exemplary embodiment of the present disclosure; [Figure 6] 6 shows a perspective view of the aerosol-generating member of FIG. 5 with the outer wrap removed, according to one embodiment of the present disclosure. [Figure 7] 1 is a bar graph showing the heat energy required to vaporize glycerol, propylene glycol, and mixtures thereof as measured by differential scanning calorimetry (DSC). [Figure 8] 1 is a graphical representation of the overlaid ionic current curves of glycerol for paper-processed reconstituted samples with various glycerol-propylene glycol loadings. [Figure 9] 1 is a graphical representation of overlaid glycerol ion current curves for beaded tobacco samples with various glycerol-propylene glycol loadings. DETAILED DESCRIPTION OF THE INVENTION

[0061] The present disclosure will now be described more fully below with reference to exemplary embodiments thereof. These exemplary embodiments are described so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Indeed, the disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. In this specification and claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. References to "percent dry weight" or "dry weight basis" refer to weight based on dry ingredients (i.e., all ingredients excluding water).

[0062] As described below, exemplary embodiments of the present disclosure relate to an aerosol-generating member comprising a substrate of two or more aerosol-forming materials, including a first aerosol-forming material and a second aerosol-forming material, wherein the first aerosol-forming material and the second aerosol-forming material have different boiling points, different vapor pressures, or both. Further exemplary embodiments of the present disclosure relate to an aerosol delivery device comprising an aerosol-generating member as disclosed herein, a heat source configured to heat the aerosol-forming materials impregnated in the substrate portion to form an aerosol, and an aerosol pathway extending from the aerosol-generating member to the mouth end of the aerosol delivery device.

[0063] Aerosol-generating members and aerosol delivery devices Some embodiments of aerosol-generating members according to the present disclosure use electrical energy to heat a material to form an inhalable substance (e.g., electrically heated tobacco products). Other embodiments of aerosol-generating members according to the present disclosure use an pyrotechnic heat source to heat a material to form an inhalable substance (preferably without burning the material to any significant extent) (e.g., carbon-heated tobacco products). Preferably, the material is heated without burning it to any significant extent. Members of such systems have the form of an article compact enough to be considered a handheld device. That is, use of preferred aerosol delivery device members does not result in the production of smoke, in the sense that the aerosol results primarily from by-products of tobacco combustion or pyrolysis; rather, use of these preferred systems results in the production of vapor resulting from the volatilization or vaporization of certain components incorporated therein. In some exemplary embodiments, aerosol delivery device members may be characterized as electronic cigarettes, which most preferably incorporate tobacco and / or tobacco-derived components and thus deliver tobacco-derived components in aerosol form.

[0064] The aerosol-generating member of certain preferred aerosol delivery devices does not burn any of its components to any substantial extent, and may provide many of the sensations (e.g., inhalation and exhalation patterns, types of tastes or flavors, sensory stimulating effects, physical feel, mode of use, visual cues such as those provided by a visible aerosol, etc.) of smoking a cigarette, cigar, or pipe used by lighting and burning tobacco (and thus inhaling tobacco smoke). For example, a user of an aerosol delivery device according to some exemplary embodiments of the present disclosure can hold and use the member just as a smoker would use a traditional type of smoking article, drawing on one end of the member to inhale the aerosol generated by the member, puffing or inhaling at selected time intervals, etc.

[0065] Although the present system is generally described herein with respect to embodiments relating to aerosol delivery devices and / or aerosol-generating members, such as so-called "electronic cigarettes" or "tobacco heating products," it should be understood that the features, members, features, and methods may be embodied in many different forms and associated with various components. For example, the description provided herein may be used with embodiments of traditional smoking articles (e.g., cigarettes, cigars, pipes, etc.), non-combustion heated cigarettes, and related packaging for any of the products disclosed herein. Accordingly, it should be understood that the description of the features, members, features, and methods disclosed herein are described with respect to embodiments relating to aerosol delivery devices by way of example only, and may be embodied and used in a variety of other products and methods.

[0066] The aerosol delivery device and / or aerosol-generating member of the present disclosure may also be characterized as a vapor product or drug delivery article. Accordingly, such articles or devices may be adapted to provide one or more substances (e.g., flavors and / or active pharmaceutical ingredients) in an inhalable form or state. For example, the inhaled substance may be substantially in the form of a vapor (i.e., a substance in the gas phase at a temperature below its critical point). Alternatively, the inhaled substance may be in the form of an aerosol (i.e., a suspension of fine solid particles or liquid droplets in a gas). For simplicity, as used herein, the term "aerosol" is meant to include vapors, gases, and aerosols in any form or type suitable for human inhalation, whether visible or not, and whether in a form that may be considered smoky. The physical form of the inhaled substance is not necessarily limited by the nature of the device of the present invention, but rather may depend on the nature of the medium and the inhaled 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 simplicity, the terms "vapor" and "aerosol" used to describe aspects of the present disclosure will be understood to be interchangeable unless otherwise specified.

[0067] In some embodiments, the aerosol delivery device of the present disclosure may comprise some combination of aerosol-generating components, including a power source (e.g., a power source), at least one control member (e.g., a means for activating, controlling, regulating, and terminating electrical power for heat generation, such as by controlling the flow of current from the power source to other components of the article, e.g., a microprocessor, either separately or as part of a microcontroller), a heat source (e.g., an electrical resistance heater or other member and / or an induction coil or other associated member and / or one or more radiant heating elements), and a substrate portion capable of generating an aerosol upon application of sufficient heat. Note that one or more of the above components can be physically combined. For example, in certain embodiments, conductive heater traces can be printed onto the surface of a substrate material (e.g., a nanocellulose substrate film) described herein using a conductive ink, such that the heater traces can be powered by a power source and used as a resistive heater. Examples of conductive inks include graphene inks and inks containing various metals, such as 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 gravure printing, flexography, offset printing, screen printing, inkjet printing, or other suitable printing methods.

[0068] In various embodiments, many of these components may be provided within an outer body or shell, which in some embodiments may be referred to as a housing. The overall design of the outer body or shell may vary, and the shape or configuration of the outer body may vary, which may define the overall size and shape of the aerosol delivery device. In some embodiments, the elongated body resembling the shape of a cigarette or cigar may be formed from a single, integral housing, or the elongated housing may be formed from two or more separable bodies, although other configurations are possible. For example, the aerosol delivery device may be substantially tubular in shape and thus comprise an elongated shell or body resembling the shape of a traditional cigarette or cigar. In one example, all components of the aerosol delivery device are contained within one housing or body. In other embodiments, the aerosol delivery device may comprise two or more joined and separable housings. For example, the aerosol delivery device may possess a control body with a housing containing one or more reusable components (e.g., an accumulator such as a rechargeable battery and / or a rechargeable supercapacitor and various electronics for controlling the operation of the item) at one end and an outer body or shell containing a disposable portion (e.g., a disposable flavor-containing aerosol-generating component) removably connectable to the other end.

[0069] In other embodiments, the aerosol-generating members of the present disclosure may generally include a pyrotechnic heat source configured to heat a substrate material. At least a portion of the substrate material and / or heat source may be covered by an outer wrap or wrapping, casing, member, module, element, or the like. The overall design of the housing may vary, as may the shape or configuration of the housing, which defines the overall size and shape of the aerosol-generating member. While other configurations are possible, in some aspects it may be desirable for the overall design, size, and / or shape of these embodiments to resemble that of a traditional cigarette or cigar. In various aspects, the heat source may be capable of generating heat to aerosolize substrate materials, including, for example, substrate materials associated with the aerosol-forming material, extruded structures and / or substrates, tobacco and / or tobacco-related materials, e.g., materials naturally found in tobacco, such as those isolated directly from tobacco or synthetically prepared, in solid or liquid form (e.g., beads, sheets, shreds, wraps), etc.

[0070] More specific shapes, configurations, and arrangements of the various substrate materials, aerosol generating components, and components within the aerosol delivery device of the present disclosure will become apparent in light of the further disclosure provided below. Additionally, the selection of various aerosol delivery device components can be understood in light of commercially available electronic aerosol delivery devices. Furthermore, the arrangement of components within the aerosol delivery device can be understood in light of commercially available electronic aerosol delivery devices.

[0071] In this regard, Figure 1 illustrates an aerosol delivery device 100 according to an exemplary embodiment of the present disclosure. The aerosol delivery device 100 may include a control body 102 and an aerosol generating member 104. In various embodiments, the aerosol generating member 104 and the control body 102 may be permanently or removably aligned in a functional relationship. In this regard, Figure 1 illustrates the aerosol delivery device 100 in a coupled configuration, while Figure 2 illustrates the aerosol delivery device 100 in a separated configuration. Various mechanisms can connect the aerosol generating member 104 to the control body 102 to provide a threaded engagement, a press-fit engagement, an interference fit, a sliding fit, a magnetic engagement, etc.

[0072] 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, those that may be defined as substantially rod-shaped, substantially tubular, or substantially cylindrical. In the embodiment of FIGS. 1-2, the device 100 has a substantially circular cross-section, although other cross-sectional shapes (e.g., oval, square, triangular, etc.) are also encompassed by the present disclosure. For example, in some embodiments, one or both of the regulator 102 or the aerosol generation member 104 (and / or any sub-components) may have a substantially rectangular shape, such as a substantially rectangular cuboid shape (e.g., similar to a USB flash drive). In other embodiments, one or both of the regulator 102 or the aerosol generation member 104 (and / or any sub-components) may have other handheld shapes. For example, in some embodiments, the regulator 102 may have a small box shape, various pod-mod shapes, or a fob shape. Thus, such language describing the physical form of the article may also apply to its individual components, including the control body 102 and the aerosol-generating member 104.

[0073] The arrangement of components within the aerosol delivery device of the present disclosure may vary across various embodiments. In some embodiments, the substrate portion may be positioned in close proximity to the heat source to maximize delivery of the aerosol to the user. However, other configurations are not excluded. Generally, the heat source may be positioned sufficiently proximate to the substrate portion so that heat from the heat source can volatilize the substrate portion (and in some embodiments, one or more flavorings, medicinal agents, etc., that may also be provided for delivery to the user) 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 should be noted that the foregoing terms, references to release, releasing, releases, or released, are meant to be interchangeable, including form or generate, forming or generating, forms or generates, and formed or generated. Specifically, the inhalant is released in the form of a vapor or an aerosol or a mixture thereof, and such terms are also used interchangeably herein, except where otherwise specified.

[0074] As described above, various embodiments of the aerosol delivery device 100 can incorporate a battery and / or other power source to provide sufficient current to provide various functionality to the aerosol delivery device, such as powering a heat source, a control system, and indicators. As described in more detail below, the power source can take various forms. Preferably, the power source can deliver sufficient power to quickly activate the heat source to provide aerosol formation and power the aerosol delivery device for a desired duration of use. In some embodiments, the power source is sized to fit conveniently within the aerosol delivery device so that the aerosol delivery device can be easily handled. Examples of useful power sources include lithium-ion batteries, preferably rechargeable (e.g., rechargeable lithium manganese dioxide batteries). In particular, lithium polymer batteries that can be used as such batteries can enhance safety. Other types of batteries, such as N50-AAA CADNICA nickel-cadmium batteries, can also be used. Additionally, preferred power sources are lightweight enough not to impair the desired smoking experience. Some examples of possible power sources are described in U.S. Pat. No. 9,484,155 to Peckerar et al. and U.S. Patent Application Publication No. 2017 / 0112191 to Sur et al., filed October 21, 2015, the disclosures of which are each incorporated by reference in their entirety herein.

[0075] In certain embodiments, one or both of the controller 102 and the aerosol-generating member 104 may be referred to as disposable or reusable. For example, the controller 102 may have a replaceable or rechargeable battery, an all-solid-state battery, a thin-film solid-state battery, a rechargeable supercapacitor, or the like, and thus may be combined with any type of charging technology, including connection to a wall charger, a car charger (i.e., cigarette lighter outlet), a computer via a Universal Serial Bus (USB) cable or connector (e.g., USB 2.0, 3.0, 3.1, USB Type-C), a photovoltaic cell (sometimes referred to as a solar cell) or solar panel, a wireless charger, such as a charger using inductive wireless charging (e.g., including wireless charging compliant with the Wireless Power Consortium (WPC) Qi wireless charging standard), or a radio frequency (RF)-based charger. An example of an inductive wireless charging system is described in U.S. Patent Application Publication No. 2017 / 0112196 to Sur et al., which is incorporated herein by reference in its entirety. Additionally, in some embodiments, the aerosol-generating member 104 may comprise a single-use device. Single-use members for use with regulators are disclosed in U.S. Patent No. 8,910,639 to Chang et al., which is incorporated herein by reference in its entirety.

[0076] In a further embodiment, the power source may also include a capacitor. Because the capacitor can discharge faster than the battery and charge between puffs, the battery can discharge the capacitor at a slower rate than if the heat source were directly powered. For example, a supercapacitor, such as an electric double layer capacitor (EDLC), can be used separately from or in combination with the battery. When used alone, the supercapacitor may be recharged before each use of the article. Therefore, the device may also include a charger member that can be attached to the smoking article during use to replenish the supercapacitor.

[0077] Additional components can be utilized in the aerosol delivery device of the present disclosure. For example, the aerosol delivery device may include a flow sensor that is sensitive to either pressure or airflow changes when a consumer inhales on an article (e.g., a puff-activated switch). Other possible current activation / deactivation mechanisms may include a temperature-activated on / off switch or a lip-pressure-activated switch. An example of a mechanism that can provide such puff-activated functionality is the Model 163PC01D36 silicon sensor manufactured by the MicroSwitch division of Honeywell, Inc., Freeport, Illinois. Representative flow sensors, current regulating components, and other current controlling components, including various microcontrollers, sensors, and switches for aerosol delivery devices, are described in U.S. Patent No. 4,735,217 to Gerth et al., U.S. Patent Nos. 4,922,901, 4,947,874, and 4,947,875, all to Brooks et al., U.S. Patent No. 5,372,148 to McCafferty et al., U.S. Patent No. 6,040,560 to Fleischhauer et al., U.S. Patent No. 7,040,314 to Nguyen et al., and U.S. Patent No. 8,205,622 to Pan, all of which are incorporated herein by reference in their entireties. Also reference is made to the control scheme described in U.S. Patent No. 9,423,152 to Ampolini et al., which is incorporated herein by reference in its entirety.

[0078] In another example, an aerosol delivery device may include a first conductive surface configured to contact a first body part of a user holding the device and a second conductive surface conductively isolated from the first conductive surface and configured to contact a second body part of the user. Thus, when the aerosol delivery device detects a change in conductivity between the first and second conductive surfaces, the vaporizer is activated to vaporize the substance, causing the vapor to be inhaled by the user holding the unit. The first and second body parts may be the lips or hands. The two conductive surfaces may also be used to charge a battery contained in the personal vaporizer unit. The two conductive surfaces may also form or be part of a connector that can be used to output data stored in the memory. U.S. Patent No. 9,861,773 to Terry et al. is incorporated herein by reference in its entirety.

[0079] Additionally, U.S. Patent No. 5,154,192 to Sprinkel et al. discloses an indicator for a smoking article; U.S. Patent No. 5,261,424 to Sprinkel, Jr. discloses a piezoelectric sensor that can be associated with the mouth end of the device to detect a user's lip movements associated with inhalation and cause heating of the heating device; U.S. Patent No. 5,372,148 to McCafferty et al. discloses a puff sensor for controlling energy flow to a heat load array in response to a pressure drop across the mouthpiece; U.S. Patent No. 5,967,148 to Harris et al. discloses a receptacle in a smoking device that includes an identifier that detects non-uniformity in infrared transmittance of an inserted member and a controller that executes a detection routine when a member is inserted into the receptacle; U.S. Patent No. 6,040,560 to Fleischhauer et al. describes defined viable power cycles with multiple differential phases; and U.S. Patent No. 5,934,289 to Watkins et al. discloses a photonic U.S. Patent No. 5,954,979 to Counts et al. discloses a means for varying the resistance to draw through a smoking device; U.S. Patent No. 6,803,545 to Blake et al. discloses particular battery configurations for use in smoking devices; U.S. Patent No. 7,293,565 to Griffen et al. discloses various charging systems for use with smoking devices; U.S. Patent No. 8,402,976 to Fernando et al. discloses a computer interface means for a smoking device to facilitate charging and enable computer control of the device; U.S. Patent No. 8,689,804 to Fernando et al. discloses an identification system for a smoking device; and PCT International Publication No. WO 2010 / 003480 to Flick discloses a fluid flow sensing system for indicating puffs in an aerosol generation system, all of the foregoing disclosures are incorporated herein by reference in their entireties.

[0080] Further examples of electronic aerosol delivery articles that may be used in the device and components related to the disclosed materials or components include U.S. Pat. No. 4,735,217 to Gerth et al., U.S. Pat. No. 5,249,586 to Morgan et al., U.S. Pat. No. 5,666,977 to Higgins et al., U.S. Pat. No. 6,053,176 to Adams et al., U.S. Pat. No. 6,164,287 to White, U.S. Pat. No. 6,196,218 to Voges, U.S. Pat. No. 6,810,883 to Felter et al., U.S. Pat. No. 6,854,461 to Nichols, U.S. Pat. No. 7,832,410 to Hon, U.S. Pat. No. 7,513,253 to Kobayashi, U.S. Pat. No. 7,896,006 to Hamano, U.S. Pat. No. 6,772,756 to Shayan, U.S. Pat. No. 6,772,756 to Hon, U.S. Pat. No. 6,832,410 to Hon, U.S. Pat. No. 6,832,410 to Hon, U.S. Pat. No. 6,513,253 to Kobayashi, U.S. Pat. No. 6,896,006 to Hamano, U.S. Pat. No. 6,772,756 to Shayan, U.S. Pat. No. 6,772,756 to Hon, U.S. Pat. No. 6,832,410 to Hon, U.S. Pat. No. 6,832,410 to Hon, U.S. Pat. No. 6, U.S. Patent Nos. 8,156,944 and 8,375,957 to Thorens et al., U.S. Patent No. 8,794,231 to Thorens et al., U.S. Patent No. 8,851,083 to Oglesby et al., U.S. Patent Nos. 8,915,254 and 8,925,555 to Monsees et al., U.S. Patent No. 9,220,302 to DePiano et al., U.S. Patent Application Publication No. 2006 / 0196 to Hon 518 and 2009 / 0188490, U.S. Patent Application Publication No. 2010 / 0024834 to Oglesby et al., U.S. Patent Application Publication No. 2010 / 0307518 to Wang, PCT International Publication No. WO2010 / 091593 to Hon, and PCT International Publication No. WO2013 / 089551 to Foo, each of which is incorporated herein by reference in its entirety. Additionally, U.S. Patent Application Publication No. 2017 / 0099877 to Worm et al., filed October 13, 2015, discloses a capsule that may be included in an aerosol delivery device and a fob configuration for an aerosol delivery device, and is incorporated herein by reference in its entirety. The various materials disclosed by the aforementioned documents may be incorporated into the device in various embodiments, and all of the foregoing disclosures are incorporated herein by reference in their entirety.

[0081] Referring to FIG. 2 , in the depicted embodiment, the aerosol-generating member 104 includes a heating end 106 configured to be inserted into the control body 102 and a mouth-end 108 that a user inhales to create an aerosol. At least a portion of the heating end 106 may include a substrate portion 110. As described in more detail below, in various embodiments, the substrate portion 110 may include various materials impregnated with an aerosol-forming material. In various embodiments, the aerosol-generating member 104, or a portion thereof, may be wrapped in an outer overwrap material 112. In various embodiments, the mouth-end 108 of the aerosol-generating member 104 may include a filter 114 made of, for example, a cellulose acetate or polypropylene material. The filter 114 may additionally or alternatively contain strands of tobacco-containing material, for example, as described in U.S. Pat. No. 5,025,814 to Raker et al., incorporated herein by reference in its entirety. In various embodiments, the filter 114 may increase the structural integrity of the mouth end of the aerosol source element and / or provide filtration capabilities and / or resistance to retraction if desired. In some embodiments, the filter may comprise individual segments. For example, some embodiments may include a segment that provides filtration, a segment that provides retraction resistance, a hollow segment that provides space for aerosol cooling, a segment that provides increased structural integrity, other filter segments, and any one or any combination of the above.

[0082] In some embodiments, the material of the outer overwrap 112 may include a material that resists heat transfer, which may include paper or other fibrous materials, such as cellulosic materials. The outer overwrap material may also include at least one filler material embedded or dispersed within the fibrous material. In various embodiments, the filler material may have the form of water-insoluble particles. Additionally, the filler material may incorporate inorganic components. In various embodiments, the outer overwrap may be formed from multiple layers, such as an underlying bulk layer and an overlying layer, such as a typical cigarette wrapper. Such materials may include, for example, lightweight "rag fibers," such as flax, tama, sisal, rice straw, and / or escarpment. The outer overwrap may also include materials typically used in conventional cigarette filter elements, such as cellulose acetate. Additionally, the excess length of the outer overlap at the mouth end 108 of the aerosol-generating member can function to simply separate the substrate portion 110 from the consumer's mouth, to provide space for placement of a filter material, to affect suction on the article, or to affect the flow characteristics of vapor or aerosol exiting the device during inhalation, as described below. Further discussion of the configuration of outer overlap materials that may be used with 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.

[0083] In various embodiments, other components may be present between the substrate portion 110 and the mouth-end 108 of the aerosol-generating member 104. For example, in some embodiments, one or any combination of the following may be disposed between the substrate portion 110 and the mouth-end 108 of the aerosol-generating member 104: an air gap, a hollow tubular structure, a phase change material for cooling air, a flavor-releasing medium, an ion-exchange fiber capable of selective chemical adsorption, aerogel particles as a filter medium, and other suitable materials. Some examples of possible phase change materials include, but are not limited to, salts such as AgNO, AlCl, TaCl, InCl, SnCl, AlI, and TiI; 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.

[0084] As described in more detail below, the presently disclosed aerosol-generating members are configured for use with conductive and / or inductive heat sources to heat a substrate material and form an aerosol. In various embodiments, the conductive heat source may comprise a heating assembly including a resistive heating element. The resistive heating element may be configured to generate heat when an electric current is directed therethrough. Conductive materials useful as resistive heating elements may have low mass, low density, and moderate resistivity, and may be thermally stable at temperatures experienced during use. Useful heating elements heat and cool rapidly, thereby providing efficient use of energy. Rapid heating of the element may be beneficial for providing nearly instantaneous volatilization of the aerosol-forming material in its vicinity. Rapid cooling prevents substantial volatilization (and therefore 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 experienced by the aerosol-forming material, particularly when time-based current control is employed. Useful conductive materials are preferably chemically non-reactive with the materials being heated (e.g., aerosol-forming materials and other inhalant materials) so as not to adversely affect the flavor or content of the aerosol or vapor produced. Some exemplary, non-limiting materials that can be used as conductive materials include carbon, graphite, carbon / graphite composites, metals, ceramics, such as metal and non-metal carbides, nitrides, oxides, silicides, intermetallic compounds, cermets, metal alloys, and metal foils. Refractory materials may be particularly useful. Various different materials can be blended to achieve desired properties of resistance, mass, and thermal conductivity. In certain embodiments, metals that can be utilized include, for example, nickel, chromium, alloys of nickel and chromium (e.g., nichrome), and steel.Materials that may be useful for providing resistive heating are described in U.S. Patent No. 5,060,671 to Counts et al., U.S. Patent No. 5,093,894 to Deevi et al., U.S. Patent No. 5,224,498 to Deevi et al., U.S. Patent No. 5,224,498 to Sprinkel et al. No. 5,228,460 to Jr. et al., U.S. Pat. No. 5,322,075 to Deevi et al., U.S. Pat. No. 5,353,813 to Deevi et al., U.S. Pat. No. 5,468,936 to Deevi et al., U.S. Pat. No. 5,498,850 to Das, U.S. Pat. No. 5,659,656 to Das, U.S. Pat. No. 5,498,855 to Deevi et al., U.S. Pat. No. 5,530,225 to Hajaligol, U.S. Pat. No. 5,665,262 to Hajaligol, U.S. Pat. No. 5,573,692 to Das et al., and U.S. Pat. No. 5,591,368 to Fleischhauer et al., the disclosures of which are incorporated herein by reference in their entireties.

[0085] In various embodiments, the heating element may be provided in a variety of forms, such as a foil, foam, mesh, hollow ball, half-ball, disk, spiral, fiber, wire, film, yarn, strip, ribbon, or cylinder. Such heating elements often comprise a metallic material and are configured to generate heat as a result of electrical resistance associated with passing an electric current therethrough. Such resistive heating elements may be positioned proximate to and / or in direct contact with the substrate portion. For example, in one embodiment, the heating element may comprise a cylinder or other heating device disposed within the control body 102, the cylinder being composed of one or more electrically conductive materials, including, but not limited to, copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, carbon (e.g., graphite), or any combination thereof. In various embodiments, the heating element may also be coated with any of these or other electrically conductive materials. The heating element may be positioned proximate the engagement end of the control body 102 and configured to substantially surround a portion of the heating end 106 of the aerosol-generating member 104, including the substrate portion 110. In this manner, when the aerosol source element is inserted into the control body 102, the heating element may be positioned proximate to the substrate portion 110 of the aerosol-generating member 104. In other examples, when the aerosol-generating member is inserted into the control body, at least a portion of the heating element may penetrate at least a portion of the aerosol-generating member (e.g., one or more prongs and / or spikes that penetrate the aerosol-generating member, etc.). Note that while in some embodiments the heating element may comprise a cylinder, in other embodiments the heating element may take various forms and, in some embodiments, may directly contact and / or penetrate the substrate portion.

[0086] In addition to being configured for use with conductive heat sources, as described above, the present disclosure may also be configured for use with inductive heat sources that heat a substrate portion to form an aerosol. In various embodiments, the inductive heat source may comprise a resonant transformer, which may comprise a resonant oscillator and a resonant receiver (e.g., a susceptor). In some embodiments, the resonant oscillator and the resonant receiver may be disposed in the control body 102. In other embodiments, the resonant receiver, or a portion thereof, may be disposed in the aerosol source element 104. For example, in some embodiments, the control body 102 may include a resonant oscillator and a resonant receiver, which may comprise, for example, a foil material, a coil, a cylinder, or other structure configured to generate an oscillating magnetic field, and the resonant receiver may comprise one or more prongs extending into or surrounded by the substrate portion. In some embodiments, the aerosol generation member is in intimate contact with the resonant receiver.

[0087] In other embodiments, the resonant oscillator may comprise a helical coil configured to surround the cavity in which the aerosol generating member, particularly the substrate portion of the aerosol generating member, is received. In some embodiments, the helical coil may be disposed between the outer wall of the device and the receiving cavity. In one embodiment, the coil winding may have a circular cross-sectional shape, while in other embodiments, the coil winding may have a variety of other cross-sectional shapes, including, but not limited to, oval, rectangular, L-shaped, T-shaped, triangular, and combinations thereof. In another embodiment, a pin may extend into a portion of the receiving cavity, and the pin may comprise a resonant oscillator, for example, by including a coil structure around or within the pin. In various embodiments, an aerosol source element may be received within the receiving cavity, and one or more components of the aerosol source element may function as a resonant receiver. In some embodiments, the aerosol generating member comprises the resonant receiver. Other possible resonant transformer components, including resonant transmitters and receivers, are described in U.S. Patent Application Publication No. 15 / 799,365, filed October 31, 2017, entitled "Induction Heated Aerosol Delivery Device," which is incorporated herein by reference in its entirety.

[0088] Base material As noted above, in various embodiments, the substrate portion 110 can include a variety of substrate materials impregnated with two or more aerosol-forming materials. In some embodiments, the substrate includes tobacco-derived fibers, wood or wood-derived fibers, or a combination thereof.

[0089] In various implementations, the tobacco-derived fibers may include ground tobacco material. Tobacco materials that may be useful in the present disclosure may vary and may include, for example, flue-cured tobacco, burley tobacco, Oriental or Maryland tobacco, dark tobacco, dark-fired tobacco, and rustica tobacco, as well as other rare or specialty tobaccos, or blends thereof. Tobacco materials may also include so-called "blend" forms and processed forms, such as processed tobacco stems (e.g., cut-rolled or cut-puffed stems), volume-expanded tobacco (e.g., puffed tobacco, such as dry ice expanded tobacco (DIET), preferably in cut filler form), and reconstituted tobacco (e.g., reconstituted tobacco produced using a papermaking or cast sheet process). Various representative tobacco types, tobacco processing types, and tobacco blend types are described in U.S. Patent No. 4,836,224 to Lawson et al., U.S. Patent No. 4,924,888 to Perfetti et al., U.S. Patent No. 5,056,537 to Brown et al., U.S. Patent No. 5,159,942 to Brinkley et al., U.S. Patent No. 5,220,930 to Gentry, U.S. Patent No. 5,360,023 to Blakley et al., U.S. Patent No. 5,360,023 to S. No. 6,701,936 to Hafer et al., U.S. Patent No. 7,011,096 to Li et al., U.S. Patent No. 7,017,585 to Li et al., U.S. Patent No. 7,025,066 to Lawson et al., U.S. Patent Application Publication No. 2004-0255965 to Perfett, WO 02 / 37990 to Bereman et al., and Bombick et al., Fund. Appl. Toxicol., Vol. 39, pp. 11-17 (1997). Further examples of tobacco compositions that may be useful are U.S. Patent No. 7,726,320 to Robinson et al., the entire contents of which are incorporated herein by reference. In some implementations, the ground tobacco material may include a blend of flavorful and aromatic tobaccos.In another implementation, the tobacco material can include reconstituted tobacco materials, such as those described in U.S. Patent No. 4,807,809 to Pryor et al., U.S. Patent No. 4,889,143 to Pryor et al., and U.S. Patent No. 5,025,814 to Raker, the entire contents of which are incorporated herein by reference. Additionally, the reconstituted tobacco material can include reconstituted tobacco paper for cigarette form, as described in Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco, R.J. Reynolds, Tobacco Company Monograph (1988), the entire contents of which are incorporated herein by reference.

[0090] In certain embodiments, the substrate comprises reconstituted tobacco material, for example, using various casting and papermaking techniques known in the art. The reconstituted tobacco material may include wood pulp, tobacco fiber, botanicals, or other cellulose components. In some embodiments, the addition of nanocellulose material to the reconstituted tobacco material may help to enhance both the absorbency and mechanical strength of the resulting material. Reconstituted tobacco materials and methods for providing such materials are described in U.S. Patent No. 4,674,519 to Keritsis et al., U.S. Patent No. 4,807,809 to Pryor et al., U.S. Patent No. 4,889,143 to Pryor et al., U.S. Patent No. 4,941,484 to Clapp et al., U.S. Patent No. 4,972,854 to Kiernan et al., U.S. Patent No. 4,987,906 to Young et al., U.S. Patent No. 5,025,625 to Raker, the entire contents of which are incorporated herein by reference. No. 814, U.S. Patent No. 5,099,864 to Young et al., U.S. Patent No. 5,143,097 to Sohn et al., U.S. Patent No. 5,159,942 to Brinkley et al., U.S. Patent No. 5,322,076 to Brinkley et al., U.S. Patent No. 5,339,838 to Young et al., U.S. Patent No. 5,377,698 to Litzinger et al., U.S. Patent No. 5,501,237 to Young, and U.S. Patent No. 6,216,707 to Kumar.

[0091] In some embodiments, the substrate comprises, by weight, about 0 to 80% tobacco-derived fiber, about 0 to about 40% tobacco-derived fiber, or about 20 to about 40% tobacco-derived fiber. In some embodiments, the substrate comprises, for example, about 0%, about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, or about 80% tobacco-derived fiber.

[0092] In some implementations, the substrate comprises a plant-derived non-tobacco material, such as, but not limited to, tama, flax, sisal, rice straw, espermum aestivum, and / or cellulose pulp material. In various other implementations, the substrate material may comprise reconstituted tobacco by itself or in combination with other fibrous materials. Some exemplary embodiments and methods for providing reconstituted tobacco sheets, including casting and papermaking techniques, are described in U.S. Pat. No. 4,674,519 to Keritsis et al., U.S. Pat. No. 4,941,484 to Clapp et al., U.S. Pat. No. 4,987,906 to Young et al., U.S. Pat. No. 4,972,854 to Kiernan et al., U.S. Pat. No. 5,099,864 to Young et al., U.S. Pat. No. 5,143,097 to Sohn et al., U.S. Pat. No. 5,159,942 to Brinkley et al., U.S. Pat. No. 5,322,076 to Brinkley et al., U.S. Pat. No. 5,339,838 to Young et al., U.S. Pat. No. 5,377,698 to Litzinger et al., U.S. Pat. No. 5,501,237 to Young, and U.S. Pat. No. 6,216,707 to Kumar, which are incorporated herein by reference in their entireties. In some cases, processed tobacco, such as certain types of reconstituted tobacco, may be used as longitudinally extending strands. See, for example, the types of configurations described in U.S. Patent No. 5,025,814 to Raker, which is incorporated herein by reference in its entirety. Furthermore, certain types of reconstituted tobacco sheets may be formed, rolled, or gathered into desired configurations. In still other implementations, the substrate material may include various types of inorganic fibers (e.g., fiberglass, metal wire / screen, etc.) and / or (organic) synthetic polymers. In various implementations, these "fibrous" materials may be unstructured (e.g., randomly dispersed, such as cellulose fibers in a tobacco cast sheet) or structured (e.g., wire mesh).

[0093] In some embodiments, the substrate comprises, by weight, about 0 to about 5% wood fibers or wood-derived fibers, e.g., 0%, about 1%, about 2%, about 3%, about 4%, or about 5% wood fibers or wood-derived fibers.

[0094] In some embodiments, the substrate portion 110 may further include a fire-resistant material, conductive fibers or particles for heat conduction / induction, or any combination thereof. One example of a fire-resistant material is ammonium phosphate. In some embodiments, other flame / burn retardant materials and additives may be included in the substrate portion 110, including organophosphorus compounds, borax, alumina trihydrate, graphite, potassium, silica, tripolyphosphate, dipentaerythritol, pentaerythritol, and polyols. Other fire-resistant materials, such as nitrogen-containing phosphonates, monoammonium phosphate, ammonium polyphosphate, ammonium bromide, ammonium borate, ethanolammonium borate, ammonium sulfamate, halogenated organic compounds, thiourea, and antimony oxide, may also be used. In each aspect of the flame-retardant, fire-resistant, and / or char-retardant materials used in the substrate material (alone or in combination with each other and / or other materials), a desirable characteristic is that they do not rely on and are resistant to undesirable gassing or melting behavior. Various embodiments and methods for incorporating tobacco into smoking articles, and in particular smoking articles designed to intentionally avoid the combustion of substantially all of the tobacco within those smoking articles, are described in U.S. Pat. No. 4,947,874 to Brooks et al., U.S. Pat. No. 7,647,932 to Cantrell et al., U.S. Pat. No. 8,079,371 to Robinson et al., U.S. Pat. No. 7,290,549 to Banerjee et al., and U.S. Patent Application Publication No. US 2007 / 0215167 to Crooks et al., the entire disclosures of which are incorporated herein by reference.

[0095] As described above, the substrate portion 110 may also include conductive fibers or particles for heating by thermal conduction or induction. In some embodiments, the conductive fibers or particles may be arranged in a substantially series and parallel pattern. In some embodiments, the conductive fibers or particles may be arranged substantially randomly. In some embodiments, the conductive fibers or particles may be comprised of aluminum materials, stainless steel materials, copper materials, carbon materials, graphite materials, and the like. In some embodiments, one or more types of conductive fibers or particles having different Curie temperatures may be included in the substrate material to facilitate inductive heating at various temperatures.

[0096] In some embodiments, the substrate further comprises one or more binders. In some embodiments, the one or more binders are selected from alginates, cellulose derivatives, starches, gums, dextran, carrageenans, calcium carbonate, or combinations thereof. Other examples of binder materials are described, for example, in U.S. Patent No. 5,101,839 to Jakob et al. and U.S. Patent No. 4,924,887 to Raker et al., which are incorporated herein by reference in their entireties.

[0097] In some embodiments, the one or more binders are alginates, such as ammonium alginate, propylene glycol alginate, potassium alginate, and sodium alginate. Alginates, especially high viscosity alginates, may be used in combination with controlled levels of free calcium ions.

[0098] In some embodiments, the substrate comprises about 0 to about 10% alginate by weight, e.g., about 0%, about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, or about 10% alginate.

[0099] In some embodiments, the one or more binders are or include one or more cellulose derivatives (e.g., a single cellulose derivative or multiple cellulose derivatives, e.g., a combination of two or three cellulose derivatives). In some embodiments, the substrate includes, by weight, about 0 to about 5% of one or more cellulose derivatives, e.g., about 0%, about 1%, about 2%, about 3%, about 4%, or about 5% of one or more cellulose derivatives. In embodiments where the substrate includes more than one cellulose derivative, it should be understood that the weight ratios provided for about 0 to about 5% of one or more cellulose derivatives reflect the total weight of the combination of cellulose derivatives.

[0100] In some embodiments, the cellulose derivative comprises a nanocellulose material. As used herein, "nanocellulose material" refers to a cellulose material having at least one average particle size dimension in the range of about 1 nm to about 100 nm. Larger cellulose material sizes may be used, but reduced aerosol-forming material loadings are likely to occur. As a non-limiting example, suitable nanocellulose materials may be fibrous materials prepared from any of a variety of cellulose-containing materials, such as wood (e.g., eucalyptus trees), grasses (e.g., bamboo), cotton, tobacco, algae, and other plant-based materials, where the fibers are further refined to produce nanofibrillated cellulose fibers. In various embodiments, the nanocellulose material may contain one or more tobacco-derived nanocellulose fibers and / or non-tobacco-derived nanocellulose fibers, optionally in combination with one or more additional cellulose materials, such as tobacco-derived cellulosic pulp and / or wood pulp-based cellulose fibers. In some embodiments, the binder material may comprise nanocellulose derived from tobacco or other biomass.

[0101] In some embodiments, one or more cellulose derivatives are chemically modified cellulose derivatives.Suitable chemically modified cellulose derivatives include hydroxypropyl cellulose, such as Klucel H manufactured by Aqualon; hydroxypropyl methylcellulose, such as Methocel K4MS manufactured by Dow Chemical; hydroxyethyl cellulose, such as Natrosol 250 MRCS manufactured by Aqualon; microcrystalline cellulose, such as Avicel manufactured by FMC; methylcellulose, such as Methocel A4M manufactured by Dow Chemical; and sodium carboxymethylcellulose, such as CMC 7HF and CMC 7H4F manufactured by Hercules.

[0102] In some embodiments, the one or more binders are starches. In some embodiments, the substrate comprises, by weight, about 0-30% starch, about 0-15% starch, or about 20-40% starch. In some embodiments, the substrate comprises, for example, about 0%, about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, or about 40% starch. Suitable starches include corn starch, rice starch, and modified food starch. In some other embodiments, the binder is rice starch. In some embodiments, the one or more binders are dextran. In some other embodiments, the binder may include cyclodextrin.

[0103] In some embodiments, the one or more binders are gums. Suitable gums include xanthan gum, guar gum, gum arabic, locust bean gum, and gum tragacanth.

[0104] In some embodiments, the one or more binders is carrageenan.

[0105] In some embodiments, the one or more binders are calcium carbonate. In some embodiments, the substrate comprises, by weight, about 0 to 60% calcium carbonate, about 45 to about 60% calcium carbonate, about 40 to about 60% calcium carbonate, or about 5 to about 15% calcium carbonate. In some embodiments, the substrate comprises, for example, about 0%, about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, or about 60% calcium carbonate.

[0106] In some embodiments, the substrate comprises, by weight, about 0 to about 60% calcium carbonate, about 0 to about 10% alginate, about 0 to about 5% one or more cellulose derivatives, about 0 to about 30% starch, about 0 to about 5% wood pulp, and about 0 to about 80% tobacco-derived fiber.

[0107] In some embodiments, the substrate comprises, by weight, about 0 to 5% calcium carbonate, about 1 to about 5% wood pulp, and about 70 to about 80% tobacco-derived fiber.

[0108] In some embodiments, the substrate comprises, by weight, about 45 to about 60% calcium carbonate, about 0 to about 10% alginate, about 0 to about 5% one or more cellulose derivatives, about 0 to about 15% starch, about 0 to about 5% wood pulp, and about 0 to about 40% tobacco-derived fiber.

[0109] In some embodiments, the substrate comprises, by weight, about 40 to about 60% calcium carbonate, about 0 to about 10% alginate, about 0 to about 5% one or more cellulose derivatives, about 0 to about 15% starch, about 0 to about 5% wood pulp, and about 0 to about 40% tobacco-derived fiber.

[0110] In some embodiments, the substrate comprises, by weight, about 5 to 15% calcium carbonate, about 1 to about 5% one or more cellulose derivatives, about 20 to about 40% starch, and about 20 to about 40% tobacco-derived fiber.

[0111] In some embodiments, the substrate is in particulate form, shredded form, film form, paper process sheet form, cast sheet form, bead form, granular rod form, or extrudate form. In various embodiments, the form of the substrate portion 110 can include gels, shreds, films, suspensions, extrudates, shavings, capsules, and / or particles (e.g., pellets, beads, strips, or any desired particle shape of various sizes), and combinations thereof. In some embodiments, the substrate is formed into a substantially cylindrical shape.

[0112] In some embodiments, the substrate is prepared using paper processing techniques, and the resulting sheet can be further divided into cut rags or strips for insertion into the substrate-containing segment of an aerosol delivery device. The preparation method generally involves hot water extraction (60-90°C) of tobacco leaves, stems, chips, or dust for a period of time. This is followed by separation (centrifugation and / or filtration) into a weak extract containing solubles and a solid fraction containing unrefined fibers. The weak extract is then concentrated to >20% solids (weight / volume), for example, by vacuum evaporation or other means. Optionally, one or more of the two or more aerosol-forming agents described herein may be added and thoroughly mixed to obtain a homogeneous mixture. Water and pre-pulped wood fiber may be added to the tobacco solids, and the material may be re-refined to fibrillate the tobacco fibers. The refined tobacco pulp may then be passed through a Fourdrinier screen to produce a nonwoven web or paper. The web may be dried to a moisture content of 45-55%. The concentrated extract containing any aerosol-forming materials may then be added back to the web and dried to a moisture content of 8-10%. Optionally, an inert filter aid may be added to the pulp prior to web formation on a Fourdrinier screen.

[0113] In a second embodiment, a cast sheet technique may be used to create a flat sheet. Cast sheets generally include a binder material, an inert filler, optionally one or more of two or more aerosol-forming agents, wood-derived fibers, and optionally botanicals, active ingredients, and / or tobacco or tobacco-derived materials, each of which is described herein. For example, in some embodiments, the fibrous material, one or more of the two or more aerosol-forming materials disclosed herein, and the binder may be blended together to form a slurry, which may be cast onto a surface (e.g., a moving belt). The cast slurry may then undergo one or more drying and / or refining steps to result in a cast sheet of relatively consistent thickness. Other examples of casting and papermaking techniques are described in U.S. Pat. No. 4,674,519 to Keritsis et al., U.S. Pat. No. 4,941,484 to Clapp et al., U.S. Pat. No. 44,987,906 to Young et al., U.S. Pat. No. 4,972,854 to Kiernan et al., U.S. Pat. No. 5,099,864 to Young et al., U.S. Pat. No. 5,143,097 to Sohn et al., U.S. Pat. No. 5,159,942 to Brinkley et al., U.S. Pat. No. 5,322,076 to Brinkley et al., U.S. Pat. No. 5,339,838 to Young et al., U.S. Pat. No. 5,377,698 to Litzinger et al., U.S. Pat. No. 5,501,237 to Young et al., and U.S. Pat. No. 6,216,706 to Kumar et al., the entire disclosures of which are incorporated herein by reference. In some embodiments, the flat sheet can be further divided into cut lugs or strips for insertion into the substrate-containing segment of an aerosol delivery device. The cast sheet can also be collected into a rod or wound into a roll for insertion into the substrate-containing segment of an aerosol delivery device.

[0114] In a third embodiment, the substrate may be prepared by granule extrusion followed by spheronization or marumerization to produce round or oval beads or hair-like rods. Granule extrusion formulations are similar to those of cast sheet formulations, except that alternative or additional binders (e.g., cellulose derivatives) are used.

[0115] In a fourth embodiment, the substrate may be prepared by extrusion followed by cutting or sizing to provide substrate pieces of multiple sizes and / or shapes. The extrusion formulation is similar to that of the granular extrusion formulation, but using additional binder combinations (e.g., combinations of cellulose derivatives).

[0116] In any of the preceding embodiments, the entire amount of aerosol-forming material may be added prior to casting, extrusion, etc. to form the aerosol-generating members disclosed herein. Alternatively, or additionally, some or all of the aerosol-forming material may be impregnated into the substrate after formation (e.g., one or more aerosol-forming materials may be sprayed or otherwise disposed into or onto the substrate material to form the aerosol-generating members disclosed herein).

[0117] Figure 3 shows a perspective schematic view of an aerosol-generating member according to an exemplary embodiment of the present disclosure. In particular, Figure 3 shows an aerosol-generating member 104 having a substrate portion 110 including a series of overlapping layers 130 of substrate 120 in sheet form. As noted above, in the illustrated embodiment, the substrate sheet 120 includes a film or layer as disclosed herein. In various embodiments, the term "overlapping layers" may also include bundled, crinkled, folded, and / or otherwise collected layers where the individual layers may not be distinct.

[0118] For example, Figure 4 shows a schematic cross-sectional view of a substrate portion of an aerosol-generating member according to an exemplary embodiment of the present disclosure. In particular, Figure 4 shows a substrate portion 110 including a series of overlapping layers 130 of a substrate sheet 120. In the illustrated embodiment, at least a portion of the overlapping layers 130 is substantially surrounded around its outer surface by a first cover layer 132. While the composition of the first cover layer 132 can vary in various embodiments, in the illustrated embodiment, the first cover layer 132 includes a combination of a fibrous material, an aerosol-forming material, and a binder material. Reference is made herein to the discussion of possible aerosol-forming materials and binder materials.

[0119] In various embodiments, the first cover layer 132 may be constructed by a casting process as described in US Pat. No. 5,697,385 to Seymour et al., which is incorporated herein by reference in its entirety.

[0120] In the illustrated embodiment, at least a portion of the overlap layer 130 and the first cover layer 132 are substantially surrounded around the outer surface by a second cover layer 134. While the composition of the second cover layer 134 can vary, in the illustrated embodiment, the second cover layer 134 comprises a metal foil material, such as an aluminum foil material. In other embodiments, the second cover layer can comprise other materials, such as, but not limited to, copper, tin, gold, alloy materials, ceramic materials, or other thermally conductive amorphous carbon-based materials, and / or any combination thereof. The illustrated embodiment further includes a third cover layer 136 that substantially surrounds the overlap layer 130, the first cover layer 132, and the second cover layer 134 along the periphery of the outer surface. In the illustrated embodiment, the third cover layer 136 comprises a paper material, such as conventional cigarette paper. In various embodiments, the paper material may include rag fibers, such as non-wood plant fibers, and may include flax, tamarisk, sisal, rice straw, and / or escarpment fibers.

[0121] Aerosol-forming materials The aerosol-generating member disclosed herein includes a substrate impregnated with two or more aerosol-forming materials, including a first aerosol-forming material and a second aerosol-forming material, each of which has a different boiling point, a different vapor pressure, or both. As used herein, reference to a "boiling point" refers to the temperature at which a liquid changes into a vapor when the vapor pressure of the liquid is equal to the pressure surrounding the liquid. When referring to a boiling point herein, the pressure surrounding the liquid is standard atmospheric pressure (i.e., 760 mmHg).

[0122] Without wishing to be bound by theory, it is believed that the presence of two or more distinct aerosol-forming materials, each having different volatilities (e.g., boiling points), allows for greater control over aerosol formation when used in an aerosol-generating device. Controlling the volume and density of the aerosol and optimizing the timing of aerosol formation from the aerosol-generating device relative to the application of heat by utilizing two or more aerosol-forming materials can enhance the consumer experience relative to the use of a single aerosol-forming material.

[0123] In some embodiments, the aerosol-forming materials have different boiling points, and the boiling points are in the range of about 100°C to about 1000°C, for example, about 100°C, about 150°C, about 200°C, about 250°C, about 300°C, or about 350°C to about 400°C, about 500°C, about 600°C, about 700°C, about 800°C, about 900°C, or about 1000°C. In some embodiments, the first aerosol-forming material has a boiling point of about 100°C, about 125°C, about 150°C, or about 175°C to about 200°C, about 225°C, or about 250°C, and the second aerosol-forming material has a boiling point of about 250°C, about 275°C, about 300°C, about 325°C, or about 350°C. In some embodiments, the difference in boiling point between the first aerosol-forming material and the second aerosol-forming material is at least 50° C. or at least 100° C. In some embodiments, the difference in boiling point between the first aerosol-forming material and the second aerosol-forming material is in the range of about 50° C. to about 300° C., e.g., about 50° C., about 100° C., about 150° C., about 200° C., about 250° C., or about 300° C.

[0124] The first and second aerosol-forming materials may be present in various ratios, with one component predominating depending on the intended application. In some embodiments, the aerosol-forming materials are present in a weight ratio of about 3:1 to about 1:3 of the first aerosol-forming material to the second aerosol-forming material. In some embodiments, the weight ratio of the first aerosol-forming material to the second aerosol-forming material is about 3:1, about 2:1, about 1:1, about 1:2, or about 1:3. In some embodiments, the weight ratio of the first aerosol-forming material to the second aerosol-forming material is about 1:1.

[0125] In some embodiments, the substrate is further impregnated with at least one additional aerosol-forming material. The additional aerosol-forming material may have a boiling point in the same range as the first aerosol-forming material or the second aerosol-forming material, or may have a different boiling point range. For example, in one non-limiting embodiment, the first and second aerosol-forming materials may have boiling points below 350°C, and the boiling point of the additional aerosol-forming material may be greater than about 350°C. In another non-limiting embodiment, the first and second aerosol-forming materials may have boiling points greater than about 175°C, and the boiling point of the additional aerosol-forming material may be less than about 175°C. In yet another non-limiting embodiment, the first and second aerosol-forming materials may have boiling points between about 175°C and about 300°C, and the boiling point of the additional aerosol-forming material may be less than about 175°C or greater than about 300°C.

[0126] In some embodiments, each of the first and second aerosol-forming materials, and any additional aerosol-forming materials that may be present, is independently selected from the group consisting of water, polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, triacetin, waxes, cannabinoids, terpenes, and sugar alcohols.

[0127] 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.

[0128] In some embodiments, the aerosol-forming material comprises one or more polysorbates. Examples of polysorbates include polysorbate 60 (polyoxyethylene (20) sorbitan monostearate, Tween 60) and polysorbate 80 (polyoxyethylene (20) sorbitan monooleate, Tween 80). The type of polysorbate used, or the combination of polysorbates used, depends on the intended desired effect, with different polysorbates providing different attributes due to their molecular size. For example, polysorbate molecules increase in size from polysorbate 20 to polysorbate 80. Using smaller polysorbate molecules produces less vapor but allows for deeper lung penetration. This may be desirable when users are in public and do not want to create a large plume of "smoke" (i.e., vapor). Conversely, larger polysorbate molecules may be used when a dense vapor capable of carrying tobacco's aromatic components is desired. An additional advantage of using compounds of the polysorbate family is that polysorbates reduce the heat of vaporization of the mixture in which they are present.

[0129] 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).

[0130] In some embodiments, the aerosol-forming material comprises one or more fatty acids. The fatty acids may include short-chain, long-chain, saturated, unsaturated, straight-chain, or branched-chain carboxylic acids. Fatty acids generally range from C4 to C6 28 aliphatic carboxylic acids. Non-limiting examples of short-chain or long-chain fatty acids include butyric acid, propionic acid, valeric acid, oleic acid, linoleic acid, stearic acid, myristic acid, and palmitic acid. In some embodiments, the aerosol-forming material includes palmitic acid.

[0131] 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 tricylate, and glycerol trihexanoate.

[0132] In some embodiments, the aerosol-forming material comprises one or more waxes, examples of which include carnauba, beeswax, and candelilla, which are known to stabilize aerosol particles, increase palatability, or reduce throat irritation.

[0133] In some embodiments, the aerosol-forming material comprises one or more cannabinoids, hi some embodiments, the cannabinoids comprise cannabidiol (CBD), tetrahydrocannabinol (THC), or a combination thereof.

[0134] In some embodiments, the aerosol-forming material comprises one or more terpenes. As used herein, the term "terpene" refers to a hydrocarbon compound produced by plants biosynthetically from isopentenyl pyrophosphate. Non-limiting examples of terpenes include limonene, pinene, farnesene, and cembrene.

[0135] In some embodiments, the aerosol-forming material comprises one or more sugar alcohols. Examples of sugar alcohols include sorbitol, erythritol, mannitol, maltitol, isomalt, and xylitol. Sugar alcohols can also act as flavor enhancers for certain flavor compounds, such as menthol and other volatiles, and generally improve the mouthfeel, texture, throat feel, and other sensory characteristics of the resulting aerosol.

[0136] In some embodiments, at least one of the first aerosol-forming material and the second aerosol-forming material is a polyhydric alcohol. In some embodiments, both the first aerosol-forming material and the second aerosol-forming material are polyhydric alcohols. In some embodiments, the polyhydric alcohol is glycerol and propylene glycol. Glycerol and propylene glycol may be present in various ratios, with either component predominating depending on the intended application, as disclosed hereinabove. For example, in some embodiments, 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.

[0137] In some embodiments, the substrate is further impregnated with at least one additional aerosol-forming agent. In some embodiments, the at least one additional aerosol-forming agent is selected from the group consisting of water, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, triacetin, sugar alcohols, cannabinoids, terpenes, and combinations thereof, each of which is described herein. In some embodiments, the first aerosol-forming material is glycerol, the second aerosol-forming material is propylene glycol, and the at least one additional aerosol-forming agent is water. In some embodiments, the first aerosol-forming material is glycerol, the second aerosol-forming material is 1,3-propanediol, and the at least one additional aerosol-forming material is water. In some embodiments, the first aerosol-forming material is glycerol, the second aerosol-forming material is propylene glycol, and the at least one additional aerosol-forming material is polysorbates. In some embodiments, the first aerosol-forming material is glycerol, the second aerosol-forming material is a sugar alcohol, and the at least one additional aerosol-forming agent is water.

[0138] In some embodiments, the substrate is loaded (e.g., incorporated or impregnated) with an aerosol-forming material described herein. The amount of aerosol-forming material incorporated (loaded) into the substrate is such that the aerosol-generating member provides acceptable sensory and desirable performance characteristics. For example, it is highly preferred that a sufficient amount of aerosol-forming material be used to generate a visible mainstream aerosol that resembles in many respects the appearance of cigarette smoke. The amount of forming material in the aerosol-generating member (e.g., impregnated substrate) can depend on factors such as the number of puffs desired per aerosol-generating member.

[0139] In some embodiments, the substrate is impregnated with at least about 15%, at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, or at least about 60% by weight of aerosol-forming material, based on the total weight of the impregnated substrate. Exemplary ranges of total aerosol-forming material include from about 15% to about 60% by weight, e.g., from about 15% to about 55%, or from about 15% to about 25% by weight, based on the total weight of the impregnated substrate. Methods of loading aerosol-forming materials onto a substrate portion are described in U.S. Pat. No. 9,974,334 to Dooly et al., U.S. Patent Application Publication No. 2015 / 0313283 to Collett et al., and U.S. Patent Application Publication No. 2018 / 0279673 to Sebastian et al., the disclosures of which are incorporated herein by reference in their entireties.

[0140] In various embodiments, loading the substrate with the aerosol-forming material is accomplished by impregnating the substrate with the aerosol-forming material during preparation of the substrate material, after formation, or both. For example, in some embodiments, a first aerosol-forming material (e.g., propylene glycol) is added to the substrate-forming slurry, e.g., during sheet fabrication, and a second aerosol-forming material (e.g., glycol) is added to the sheet (e.g., by spraying) as a top dressing to form the impregnated substrate (i.e., aerosol-generating member). In other embodiments, both the first and second aerosol-forming materials are added to the substrate-forming slurry. In some embodiments, additional aerosol-forming materials may be impregnated into the substrate, either in the substrate-forming slurry or as a top dressing. As will be appreciated by those skilled in the art, multiple permutations of methods for loading the substrate with the aerosol-forming material are possible, depending on the particular substrate material, morphology, etc. Accordingly, such variations are contemplated herein.

[0141] In some embodiments, the substrate is further impregnated with an active ingredient, a flavoring agent, or a combination thereof, each of which is further described herein below.

[0142] Active ingredient In certain embodiments, the substrate is further impregnated with one or more active ingredients. The active ingredient may be a component of the aerosol-forming material or may be impregnated separately. Impregnation may occur during preparation of the substrate material, after formation of the substrate, or both. As used herein, "active ingredient" refers to one or more substances belonging to any of the following categories: APIs (active pharmaceutical substances), food additives, natural medicines, and substances of natural origin that may have an effect on humans. Examples of active ingredients include any ingredient known to affect one or more biological functions in the body, such as ingredients that provide pharmacological activity or other direct effects in the diagnosis, cure, mitigation, treatment, or prevention of disease, or ingredients that affect the structure or any function of the human body (e.g., ingredients that provide a stimulating effect on the central nervous system, an energizing effect, an antipyretic or analgesic effect, or another beneficial effect on the body). In some embodiments, the active ingredient may be of the type commonly referred to as a dietary supplement, nutraceutical, "botanical compound," or "functional food." These types of additives are sometimes defined in the art to encompass substances typically available from natural sources (e.g., botanical materials) that provide one or more beneficial biological effects (e.g., health promotion, disease prevention, or other medicinal properties), but are not classified or regulated as drugs. Non-limiting examples of active ingredients include those belonging to the categories of synthetic organic compounds, proteins and peptides, polysaccharides and other sugars, lipids, inorganic compounds, and nucleic acid sequences, which have therapeutic, preventative, or diagnostic utility. Non-limiting examples of active ingredients include those belonging to the categories of botanical ingredients, stimulants (e.g., caffeine and guarana), amino acids (e.g., taurine, theanine, phenylalanine, tyrosine, and tryptophan), and / or pharmaceutical, nutraceutical, and medicinal ingredients (e.g., vitamins, e.g., B6, B12, and C), cannabinoids (e.g., tetrahydrocannabinol (THC) and cannabidiol (CBD)), antioxidants, and nicotine ingredients. The particular choice of active ingredient will depend on the desired flavor, texture, and desired characteristics of the particular product.

[0143] The specific percentage of active ingredients present will vary depending on the desired properties of a particular product. Typically, the active ingredient or combination thereof is present in a total concentration of at least about 0.001% by weight of the composition, e.g., in the range of about 0.001% to about 20%. In some embodiments, the active ingredient or combination of active ingredients is present in a concentration of about 0.1% (w / w) to about 10% by weight, e.g., about 0.5% (w / w) to about 10% by weight, 1% to about 10% by weight, or about 1% to about 5% by weight, based on the total weight of the composition. In some embodiments, the active ingredient or combination of active ingredients is present in an amount of about 0.001%, about 0.01%, about 0.1%, or about 1% to about 20% by weight, based on the total weight of the composition, for example, about 0.001%, about 0.002%, about 0.003%, about 0.004%, about 0.005%, about 0.006%, about 0.007%, about 0.008%, about 0.009%, about 0.01%, about 0.02%, about 0.03%, about 0.04%, about 0. ... The active ingredient is present in a concentration of about 0.06%, about 0.07%, about 0.08%, about 0.09%, about 0.1%, about 0.2%, about 0.3%, about 0.4%, about 0.5%, about 0.6%, about 0.7%, about 0.8%, or about 0.9% to about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about 10%, about 11%, about 12%, about 13%, about 14%, about 15%, about 16%, about 17%, about 18%, about 19%, or about 20% by weight. Further suitable ranges for particular active ingredients are provided herein below.

[0144] In some embodiments, the active ingredient comprises one or more non-tobacco botanicals. As used herein, the terms "botanical ingredient" or "botanical" refer 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 that has been subjected to heat treatment, fermentation, or other treatment processes that can alter the chemical properties of the material). For purposes of this disclosure, "botanical material" includes, but is not limited to, "herbal material." "Herbal material" refers to seed-producing plants (e.g., tea or tisane) that do not develop perennial woody tissue and are often valued for their medicinal or sensory properties. Reference to plant material as "non-tobacco" is intended to exclude tobacco material (i.e., not including Nicotiana species). Botanical materials useful in the present disclosure may include, but are not limited to, any of the compounds and sources described herein, as well as mixtures thereof. Certain botanical materials of this type are sometimes called dietary supplements, nutraceuticals, "phytocompounds" or "functional foods."

[0145] Non-limiting examples of botanical ingredients, many of which are associated with antioxidant properties, include acai berry, alfalfa, allspice, annatto seed, apricot oil, basil, bee balm, wild bergamot, black pepper, blueberry, borage seed oil, lily of the valley, cacao, calamus root, catnip, catuaba, cayenne pepper, chaga mushroom, chervil, cinnamon, dark chocolate, potato skin, grape seed, ginseng, and ginkgo biloba. biloba), St. John's wort, saw palmetto, green tea, black tea, black cohosh, cayenne, chamomile, cloves, cocoa powder, cranberry, dandelion, grapefruit, honeybush, echinacea, garlic, evening primrose, feverfew, ginger, goldenseal, hawthorn, hibiscus flower, gynostemma, kava, lavender, licorice, marjoram, milk thistle, mint, oolong tea, beetroot, orange, oregano, papaya, pennyroyal, peppermint, red clover, rooibos (red or green), rosehip, rosemary, sage, clary sage, savory, spearmint, spirulina, slippery elm bark, sorghum bran (high-tannin), sumac bran Bran, comfrey leaves and root, goji berry, gotu kola, thyme, turmeric, va-ursi, valerian, wild yam root, wintergreen, yacon root, yellow dock, yerba mate, yerba santa, bacopa monniera, withania somnifera, Yamabushitake mushroom, and silybum marianum. Further non-limiting examples of botanical materials include thyme, eucalyptus, fennel, rooibos, citrus fruits, clove, chamomile, cannabis, maca, and tisane.

[0146] If present, botanicals are typically at a concentration of about 0.01% (w / w) to about 10% by weight, for example, about 0.01% (w / w), about 0.05%, about 0.1%, or about 0.5% to about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, or about 10%, about 11%, about 12%, about 13%, about 14%, or about 15% by weight, based on the total weight of the composition.

[0147] In some embodiments, the active ingredient comprises a nicotine component. By "nicotine component" is meant nicotine in any suitable form (e.g., free base or salt) to provide systemic absorption of at least a portion of the nicotine present. Typically, the nicotine component is selected from the group consisting of nicotine free base and nicotine salts. In some embodiments, the nicotine is in free base form. The nicotine can be tobacco-derived (e.g., tobacco extract) or non-tobacco-derived (e.g., synthetically or otherwise obtained). In various embodiments, the impregnated substrate can comprise a nicotine component. In various embodiments, the impregnated substrate can be free of a nicotine component. In some embodiments, the impregnated substrate can comprise a non-tobacco-derived nicotine component.

[0148] Typically, the nicotine component (calculated as the free base), when present, is at a concentration of at least about 0.001% by weight of the impregnated substrate, e.g., in the range of about 0.001% to about 10% by weight. In some embodiments, the nicotine component, calculated as the free base, is present in a concentration of about 0.1% to about 10% by weight, e.g., about 0.1%, about 0.2%, about 0.3%, about 0.4%, about 0.5%, about 0.6%, about 0.7%, about 0.8%, or about 0.9% to about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, or about 10% by weight, based on the total weight of the impregnated substrate. In some embodiments, the nicotine component, calculated as the free base, is present in a concentration of about 0.1% w / w to about 3% w / w, e.g., about 0.1% to about 2.5% w / w, about 0.1% to about 2.0% w / w, about 0.1% to about 1.5% w / w, or about 0.1% to about 1% w / w, based on the total weight of the impregnated substrate. These ranges may also apply to other active ingredients described herein.

[0149] In some embodiments, the oral compositions of the present disclosure may be characterized as being completely free or substantially free of nicotine components. "Substantially free of nicotine components" means that no nicotine has been intentionally added, except for trace amounts that may be naturally present, for example, in botanical materials. For example, certain embodiments may be characterized as having less than 0.001% nicotine by weight, or less than 0.0001% by weight, or even 0% nicotine by weight, calculated as the free base.

[0150] In some embodiments, the active ingredient comprises a tobacco component (e.g., a tobacco extract). In various embodiments, the tobacco material may be processed to extract soluble components of the tobacco material. As used herein, "tobacco extract" refers to an isolated component of the tobacco material extracted from solid tobacco pulp by a solvent that contacts the tobacco material in an extraction process. Various extraction techniques for tobacco materials may be used to provide the tobacco extract and tobacco solid material. See, for example, the extraction process described in U.S. Patent Application Publication No. 2011 / 0247640 to Beeson et al., which is incorporated herein by reference.Other exemplary techniques for extracting tobacco components include U.S. Pat. Nos. 4,144,895 to Fiore, 4,150,677 to Osborne, Jr. et al., 4,267,847 to Reid, 4,289,147 to Wildman et al., 4,351,346 to Brummer et al., 4,359,059 to Brummer et al., 4,506,682 to Muller et al., and 4,589,428 to Keritsis, all of which are incorporated herein by reference. , Soga et al., No. 4,605,016, Poulose et al., No. 4,716,911, Niven, Jr. et al., No. 4,727,889, Bernasek et al., No. 4,887,618, Clapp et al., No. 4,941,484, Fagg et al., No. 4,967,771, Roberts et al., No. 4,986,286, Fagg et al., No. 5,005,593, Grubbs et al., No. 5,018,540, White et al., No. 5,060,669, Fagg et al. No. 5,065,775 to White et al.; No. 5,074,319 to White et al.; No. 5,099,862 to White et al.; No. 5,121,757 to White et al.; No. 5,131,414 to Fagg; No. 5,131,415 to Munoz et al.; No. 5,148,819 to Fagg; No. 5,197,494 to Kramer; No. 5,230,354 to Smith et al.; No. 5,234,008 to Fagg; No. 5,243,999 to Smith; No. 5,3 No. 01,694 to Gonzalez-Parra et al., No. 5,318,050 to Teague, No. 5,343,879 to Newton, No. 5,360,022 to Newton, No. 5,435,325 to Clapp et al., No. 5,445,169 to Brinkley et al., No. 6,131,584 to Lauterbach, No. 6,298,859 to Kierulff et al., No. 6,772,767 to Mua et al., and No. 7,337,782 to Thompson.

[0151] Typical inclusion ranges of tobacco components may vary depending on the nature and type of tobacco material and the intended use of the aerosol-generating component. In some embodiments, products of the present disclosure may be characterized as being completely free or substantially free of tobacco components (other than purified nicotine as the active ingredient). For example, certain embodiments may be characterized as having less than 1% by weight, or less than 0.5% by weight, or less than 0.1% by weight, or less than 0.01% by weight, or even 0% by weight of tobacco components.

[0152] Flavoring agents As mentioned above, the impregnated substrate may also contain a flavoring agent. The active ingredient may be a part of the aerosol-forming material or may be impregnated separately. Impregnation can be performed during preparation of the substrate material, after formation of the substrate, or both. As used herein, reference to a "flavoring agent" refers to a compound or agent that can be aerosolized and delivered to a user and that provides a sensory experience in terms of taste and / or aroma. Flavoring agents may be natural or synthetic, and the flavor characteristics imparted thereby may be described, without limitation, as fresh, sweet, herbal, confectionery, floral, fruity, or spicy. Some examples of flavoring agents include, but are not limited to, vanillin, ethyl vanillin, cream, tea, coffee, fruit (e.g., apple, cherry, strawberry, peach, and citrus flavors including lime, orange, and lemon), maple, menthol, eucalyptus, mint, peppermint, spearmint, wintergreen, cascarilla, nutmeg, clove, lavender, cardamom, ginger, honey, anise, sage, rosemary, hibiscus, rosehip, yerba mate, guayusa, honeybush, rooibos, yerba santa, bacopa monnieri, ginkgo biloba, withania somnifera, cinnamon, sandalwood, jasmine, cascarilla, cocoa, licorice, trigeminal sensate, terpene, and any combination thereof. As used herein, "trigeminal sensate" refers to a flavoring agent that acts on the trigeminal nerve to produce sensations such as heating, cooling, or tingling. Non-limiting examples of trigeminal sensate flavoring agents include capsaicin, citric acid, menthol, cinnamon, erythritol, and cubebol. Further non-limiting examples include flavors and flavor packages of the types and characteristics traditionally used in cigarette, cigar, and pipe tobacco flavorings. See also Leffingwell et al., "Tobacco Flavoring for Smoking Products," R.J. Reynolds Tobacco Company (1972), incorporated herein by reference. Flavoring agents may include terpenes, terpenoids, aldehydes, ketones, esters, and other compounds.Syrups, such as high fructose corn syrup, can also be used. Some examples of plant-derived compositions that may be suitable are described in U.S. Patent No. 9,107,453 and U.S. Patent Application Publication No. 2012 / 0152265, both to Dube et al., the disclosures of which are incorporated herein by reference in their entireties. The selection of such additional ingredients can vary based on factors such as the sensory characteristics desired in the smoking article, their affinity for the substrate material, their solubility, and other physicochemical properties. The present disclosure is intended to encompass any such additional ingredients that would be readily apparent to one 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 entireties. It should be noted that reference to flavoring agents should not be limited to any single flavoring agent listed above, and may, in fact, represent a combination of one or more flavoring agents. Additional flavors, flavorings, additives and other possible enhancing ingredients are described in US Patent Application Publication No. 15 / 707,461 to Phillips et al., which is incorporated herein by reference in its entirety.

[0153] The amount of flavoring agent present can vary and, if present, is generally less than about 30% or less than about 20% by weight of the impregnated substrate. For example, the flavoring agent may be present in an amount of about 0.1%, about 0.5%, about 1%, or about 5% to about 10%, about 20%, or about 30% by weight of the impregnated substrate.

[0154] Aerosol Delivery Device As described herein, in another aspect, there is provided an aerosol delivery device comprising: an aerosol-generating member as described herein; a heat source configured to heat an aerosol-forming material impregnated in a substrate portion to form an aerosol; and an aerosol pathway extending from the aerosol-generating member to a mouth end of the aerosol delivery device.

[0155] In some embodiments, the aerosol-generating member and the controller may be provided together as a complete smoking article or drug delivery article, although these components may also be provided separately. For example, the present disclosure also encompasses disposable units for use with reusable smoking articles or reusable drug delivery articles. In certain embodiments, such disposable units (which may be the aerosol-generating member shown in the accompanying drawings) may include a substantially tubular-shaped body having a heating end configured to engage with the reusable smoking article or drug delivery article, an opposing mouth end configured to allow passage of an inhalable substance to a consumer, and a wall having outer and inner surfaces defining an interior space. Various embodiments of aerosol-generating members (or cartridges) are described in U.S. Patent No. 9,078,473 to Worm et al., which is incorporated herein by reference in its entirety.

[0156] Although some of the figures described herein show the regulator and aerosol-generating member in an operative relationship, it is understood that the regulator and aerosol-generating member may exist as separate devices, and therefore any discussion provided elsewhere herein regarding combined members should be understood to apply to the regulator and aerosol-generating member as individual and separate members.

[0157] In another aspect, the present disclosure relates to kits providing various components described herein. For example, the kit may include a controller having one or more aerosol-generating components. The kit may further include a controller having one or more charging components. The kit may further include a controller with one or more batteries. The kit may further include a controller having one or more aerosol-generating components and one or more charging components and / or one or more batteries. In further embodiments, the kit may include multiple aerosol-generating components. The kit may further include multiple aerosol-generating components and one or more batteries and / or one or more charging components. In the above embodiments, the aerosol-generating components or the controller may be provided with a heating element enclosed therein. The kits of the present invention may further include a case (or other packaging, carrying, or storage component) for housing one or more additional kit components. The case may be a reusable rigid or flexible container. Furthermore, the case may simply be a box or other packaging structure.

[0158] Figure 5 shows a perspective view of an aerosol-generating member according to another exemplary embodiment of the present disclosure, and Figure 6 shows a perspective view of the aerosol-generating member of Figure 5 with the outer wrap removed. In particular, Figure 5 shows the aerosol-generating member 200 including the outer wrap 202, and Figure 6 shows the aerosol-generating member 200 with the outer wrap 202 removed to reveal the other components of the aerosol-generating member 200. In the illustrated embodiment, the aerosol-generating member 200 of the illustrated embodiment comprises a heat source 204, a substrate portion 210, an intermediate member 208, and a filter 212. In the illustrated embodiment, both the intermediate member 208 and the filter 212 comprise a mouthpiece 214.

[0159] Although the aerosol delivery device and / or aerosol-generating member according to the present disclosure may take various forms, as described in detail below, the use of the aerosol delivery device and / or aerosol-generating member by a consumer is similarly within the scope of the present invention. The foregoing description of the aerosol delivery device and / or aerosol-generating member is applicable to the various embodiments described with minor modifications that will be apparent to those skilled in the art in light of the further disclosure provided herein. However, the description of use is not intended to limit the use of the articles of the present disclosure, but is provided to meet all necessary requirements of the disclosure herein.

[0160] In various embodiments, the heat source 204 may be configured to generate heat upon ignition. In the illustrated embodiment, the heat source 204 has a generally cylindrical shape and includes a combustible fuel element incorporating a combustible carbon material. In other embodiments, the heat source 204 may have a different shape, such as a prismatic shape with a triangular, cubic, or hexagonal cross section. Carbonaceous materials generally have a high carbon content. Preferred carbonaceous materials may be primarily composed of carbon and / or may typically have a carbon content of greater than about 60%, commonly greater than about 70%, often greater than about 80%, and often greater than about 90%, on a dry weight basis.

[0161] In some examples, heat source 204 may incorporate elements other than combustible carbonaceous material (e.g., tobacco components, such as powdered tobacco or tobacco extract; flavoring agents; salts, such as sodium chloride, potassium chloride, and sodium carbonate; thermally stable graphite fibers; iron oxide powder; glass filaments; powdered calcium carbonate; alumina granules; an ammonia source, such as an ammonia salt; a binder, such as guar gum, ammonium alginate, and sodium alginate; and / or a phase change material for reducing the temperature of the above heat sources). While the specific dimensions of applicable heat sources may vary, in some embodiments, heat source 204 may have a length in the inclusive range of about 7 mm to about 20 mm, and in some embodiments, may be about 17 mm, and an overall diameter in the inclusive range of about 3 mm to about 8 mm, and in some embodiments, may be about 4.8 mm (and in some embodiments, about 7 mm). In other embodiments, the heat source can be configured in various ways, but in the illustrated embodiment, the heat source 204 is extruded or compounded using ground or powdered carbonaceous material, with a dry weight basis of approximately 0.5 g / cm 3 greater, often around 0.7 g / cm 3 , often about 1 g / cm 3It has a greater density. See, for example, the types of fuel source components, formulations, and designs described in U.S. Patent No. 5,551,451 to Riggs et al. and U.S. Patent No. 7,836,897 to Borschke et al., which are incorporated herein by reference in their entireties. In various embodiments, the heat source can have a variety of forms, including, for example, a substantially solid cylindrical shape or a hollow cylindrical (e.g., tubular) shape; the heat source 204 in the illustrated embodiment is generally cylindrical but comprises an extruded monolithic carbonaceous material having a plurality of grooves 216 extending longitudinally from a first end of the extruded monolithic carbonaceous material to an opposing second end of the extruded monolithic carbonaceous material. In some embodiments, the aerosol delivery device, particularly the heat source, can include a heat transfer component. In various embodiments, the heat transfer component can be proximate to the heat source, and in some embodiments, the heat transfer component can be disposed in or within the heat source. Some examples of heat transfer components are described in U.S. Patent Application No. 15 / 923,735, filed March 16, 2018, entitled Smoking Article with Heat Transfer Component, which is incorporated herein by reference in its entirety.

[0162] In the illustrated embodiment, the grooves 216 in the heat source 204 are substantially equal in width and depth and substantially evenly distributed around the circumference of the heat source (204), although other embodiments may include two grooves, and still other embodiments may include a single groove. Still other embodiments include no grooves at all. Additional embodiments may include grooves that may be unequal in width and / or depth and may be unevenly spaced around the circumference of the heat source. In still other embodiments, the heat source may include grooves and / or slits extending longitudinally from a first end to an opposing second end of the extruded monolithic carbonaceous material. In some embodiments, the heat source may include a foamed carbon monolith formed during a foaming process of the type disclosed in U.S. Patent No. 7,615,184 to Lobovsky, which is incorporated herein by reference in its entirety. As such, some embodiments may provide advantages related to reduced time required to ignite the heat source. In other embodiments, the heat source is co-extruded with an insulating layer (not shown), thereby reducing manufacturing time and costs. Other embodiments of the fuel element include carbon fiber of the type described in U.S. Pat. No. 4,922,901 to Brooks et al., or other heat source embodiments disclosed in U.S. Patent Application Publication No. 2009 / 0044818 to Takeuchi et al., which are incorporated herein by reference in their entireties.

[0163] Generally, a heat source is positioned sufficiently close to an aerosol-generating member (e.g., a substrate portion) having one or more aerosolizable elements such that the aerosol (and any flavorings, medicaments, etc. similarly provided for delivery to the user) formed / volatilized by applying heat from the heat source to the aerosolizable elements is deliverable to a 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. Note that the foregoing terms mean that references to release, releasing, releases, or released are interchangeable to include form or generate, forming or generating, forms or generates, and formed or generated. Specifically, the inhalable substance is released in the form of a vapor or an aerosol or a mixture thereof. Additionally, the selection of various aerosol delivery device components will be appreciated in light of commercially available electronic aerosol delivery devices, such as the representative products listed in the Background section of this disclosure.

[0164] 5 and 6 , the outer wrap 202 may be configured to engage or otherwise join at least a portion of the heat source 204, the substrate portion 210, and at least a portion of the mouthpiece 214. In various embodiments, the outer wrap 202 is configured to be held in the wrapped position in any manner, such as via adhesive, fasteners, or the like, to allow the outer wrap 202 to remain in the wrapped position. Alternatively, in some other embodiments, the outer wrap 202 may be configured to be removable as desired. For example, once the outer wrap 202 is held in the wrapped position, the outer wrap 202 can be removed from the heat source 204, the substrate portion 210, and / or the mouthpiece 214.

[0165] In some embodiments, in addition to the outer wrap 202, the aerosol delivery device may also include a liner configured to circumscribe at least a portion of the substrate portion 210 and the heat source 204. In other embodiments, the liner may circumscribe only a portion of the length of the substrate portion 210, while in some embodiments, the liner may circumscribe substantially the entire length of the substrate portion 210. In some embodiments, the outer wrap material 202 may include a liner. Thus, in some embodiments, the outer wrap material 202 and the liner may be separate materials provided together (e.g., glued, fused, or otherwise joined together as a laminate). In other embodiments, the outer wrap 202 and the liner may be the same material. In either case, the liner may be configured to thermally regulate the conduction of heat generated by the ignited heat source 204 radially outward of the liner. Thus, in some embodiments, the liner may be constructed from a metal foil material, an alloy material, a ceramic material, or other thermally conductive amorphous carbon-based material, and / or an aluminum material. In some embodiments, a laminate may be included. In some embodiments, depending on the material of the outer wrap 202 and / or liner, a thin insulating layer may be provided radially outward of the liner. Thus, the liner may in some aspects advantageously provide a method of engaging two or more separate components of the aerosol-generating member 200 (e.g., the heat source 204, the substrate portion 210, and / or portions of the mouthpiece 214) while facilitating axial heat transfer along the axial direction but limiting radially outward heat conduction.

[0166] 5, the outer wrap 202 (and, if necessary, the liner and substrate portion 210) may include one or more openings to allow air intake upon inhalation at the mouthpiece 214. In various embodiments, the size and number of these openings may vary based on specific design requirements. In the illustrated embodiment, a plurality of openings 220 are located proximate the end of the substrate portion 210 closest to the heat source 204, and a plurality of separate cooling openings 221 are formed in the outer wrap 202 (or, in some embodiments, the liner) in the region of the mouthpiece 214 proximate the filter 212. Other embodiments differ from the illustrated embodiment in that the openings 220 comprise a plurality of openings substantially evenly spaced around the outer surface of the aerosol-generating member 200, and the openings 221 also comprise a plurality of openings substantially evenly spaced around the outer surface of the aerosol-generating member 200. In various embodiments, multiple openings may be formed through the outer wrap 202 (and in some embodiments, the liner), but in the illustrated embodiment, the multiple openings 220 and multiple separate cooling openings 221 are formed through laser drilling.

[0167] Referring to FIG. 6 , the illustrated embodiment of the aerosol-generating member 200 includes an intermediate member 208 and at least one filter 212. Note that in various embodiments, the intermediate member 208 or the filter 212, individually or together, can be considered the mouthpiece 214 of the aerosol-generating member 200. While neither an intermediate member nor a filter need be included in various embodiments, in the illustrated embodiment, the intermediate member 208 includes a substantially rigid member that is substantially inflexible along its longitudinal axis. In the illustrated embodiment, the intermediate member 208 includes a hollow tubular structure and is included to add structural integrity to the aerosol-generating member 200 and to cool the generated aerosol. In some embodiments, the intermediate member 208 can be used as a container for collecting the aerosol. In various embodiments, such components can be constructed from any of a variety of materials and can include one or more adhesives. Exemplary materials include, but are not limited to, paper, paper layers, paperboard, plastic, cardboard, and / or composite materials. In the illustrated embodiment, the intermediate member 208 comprises a hollow cylindrical element constructed from paper or a plastic material (e.g., ethyl acetate (EVA), or other polymeric material such as polyethylene, polyester, silicone, etc., or ceramics (e.g., silicon carbide, alumina, etc.), or other acetate fibers), and the filter comprises a pack rod or cylindrical disk constructed from a gas permeable material (e.g., cellulose acetate or fibers such as paper or rayon, or polyester fibers).

[0168] As noted above, in some embodiments, the mouthpiece 214 may include a filter 212 configured to allow aerosol to pass therethrough in response to drawing on the mouthpiece 214. In various embodiments, the filter 212 is provided as a circular disk, in some aspects, radially and / or longitudinally disposed adjacent the second end of the intermediate member 208. In this manner, upon drawing on the mouthpiece 214, the filter 212 receives the aerosol flowing through the intermediate member 208 of the aerosol-generating member 200. In some embodiments, the filter 212 may include separate segments. For example, some embodiments provide segments that provide filtering, segments that provide stretch resistance, hollow segments that provide space for the aerosol to cool, segments that provide increased structural integrity, other filter segments, and any one or any combination of the above. In some embodiments, the filter 212 may additionally or alternatively include strands of tobacco-containing material, such as those described in U.S. Patent No. 5,025,814 to Raker et al., incorporated herein by reference in its entirety.

[0169] In various embodiments, the size and shape of intermediate member 208 and / or filter 212 may vary, for example, the length of intermediate member 208 may be in the inclusive range of about 10 mm to about 30 mm, the diameter of intermediate member 208 may be in the inclusive range of about 3 mm to about 8 mm, and the length of filter 212 may be in the inclusive range of about 10 mm to about 20 mm, and the diameter of filter 212 may be in the inclusive range of about 3 mm to about 8 mm. In the illustrated embodiment, intermediate member 208 has a length of about 20 mm and a diameter of about 4.8 mm (and in some embodiments, about 7 mm), and filter 212 has a length of about 15 mm and a diameter of about 4.8 mm (or in some embodiments, about 7 mm).

[0170] In various embodiments, ignition of the heat source 204 results in aerosolization of the aerosol-forming material associated with the substrate portion 210. Preferably, elements of the substrate portion 210 do not thermally decompose (e.g., char, scorch, or burn) to any significant extent, and the aerosolized components are carried along in the airflow drawn through the aerosol-generating member 200, including the filter 212, and into the user's mouth. In various embodiments, the mouthpiece 214 (e.g., the intermediate member 208 and / or the filter 212) is configured to pass the generated aerosol in response to a draw applied by the user to the mouthpiece 214. In some embodiments, the mouthpiece 214 can be fixedly engaged to the substrate portion 210. For example, adhesives, bonds, welding, or the like may be suitable for fixedly engaging the mouthpiece 214 to the substrate portion 210. In one example, the mouthpiece 214 is ultrasonically welded and sealed at the ends of the substrate portion 210.

[0171] Many modifications and other embodiments of the present disclosure will be apparent to those skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the corresponding drawings. It is to be understood, therefore, that the present disclosure is not limited to the particular embodiments disclosed herein, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. [Example]

[0172] Aspects of the present invention will be more fully illustrated by the following examples, which are provided to illustrate particular aspects of the disclosure and should not be construed as limiting the invention.

[0173] Example 1: Papermaking Process Preparation of Heat-Not-Burning (HNB) Aerosol-Forming Agent Substrate Aerosol former substrate 1A (reference substrate) Tobacco (leaf and stem, 400 lb) was mixed with 10 times its weight in water and extracted in a counter extractor at 70°C for 1 hour. The contents of the extractor were then centrifuged to separate a thin tobacco extract (3-4% w / v) and undissolved tobacco solids. The thin extract was transferred to a vacuum evaporator and concentrated to 23% solids (w / v). Glycerol (75 lb) was added and the mixture was thoroughly mixed to obtain the final liquid composition. Pre-refined wood pulp (25 lb) was mixed with the tobacco solids, and sufficient water was added to bring the mixture to 1% solids (w / v). The total batch weight was 500 lb. The wood pulp-tobacco solids mixture was refined using a disc refiner to obtain fibrillated tobacco pulp. The fibrillated tobacco pulp was conveyed to a headbox and discharged onto a Fourdrinier wire machine to obtain a wet web or base sheet. The base sheet was dried to a moisture content of 40-55%. The final liquid composition was returned to the wet web (spray method) and the wet web was dried to a moisture content of 8-10% (w / w). The resulting sheet was then cut into leaflet pieces.

[0174] Aerosol-Forming Agent Substrates 1Bi and 1Bii (Substrates of the Invention) Aerosol-forming Substrate 1Bi was prepared similarly to Substrate 1A, except that the wood pulp was removed and the glycerol was replaced with a 75 / 25 mixture by weight of glycerol and propylene glycol. For Aerosol-Forming Substrate 1Bii, calcium carbonate (present as a filler and drainage aid) was mixed with half of the fibrillated tobacco pulp prior to forming a wet web. The total batch weight was 300 lb (150 lb for each substrate).

[0175] Aerosol-Forming Agent Substrate 1C (Substrate of the Invention) Aerosol-forming Substrate 1C was prepared similarly to Substrate 1A, except that the glycerol was replaced with a 50 / 50 mixture by weight of glycerol and propylene glycol. The total batch weight was 300 lb.

[0176] Aerosol-Forming Agent Substrate 1D (Substrate of the Invention) Aerosol former Base 1D was prepared similarly to Base 1A, except the glycerol was replaced with a 25 / 75 by weight mixture of glycerol and propylene glycol. The total batch weight was 300 lb. See Table 1.

[0177] Aerosol former substrate 1E (reference substrate) Aerosol-forming Substrate 1E was prepared similarly to Substrate 1B, except glycerol was replaced with propylene glycol. The total batch weight was 300 lb. See Table 1.

[0178] [Table 1]

[0179] Example 2: Cast Sheet Preparation of HNB Aerosol-Forming Agent Substrate Aerosol former substrate 2A (reference substrate) Sodium alginate (50 lb) was slowly added to water (1650 lb) and hydrated under vacuum for 30 minutes in a high-shear mixing tank. In a separate mixing tank, calcium carbonate (250 lb) was slowly added to glycerol (100 lb) and tobacco extract powder (100 lb), followed by gentle mixing for 30 minutes to form a slurry. The hydrated alginate was then mixed with zero-freeness pre-refined wood pulp, then transferred to the calcium carbonate slurry, which was then mixed for an additional 30 minutes under medium mixing speed and vacuum to obtain the final slurry. The final slurry was then cast onto a 22-inch-wide stainless steel conveyor belt using a casting knife set at a 1-3 mm gap opening. The cast material or film was then dried into a flat sheet by conveying the film through a 200-foot convection tunnel dryer containing multiple heating zones (80-100°C). The total batch weight was 500 lb. The flat sheet was wound onto a bobbin and vacuum sealed in a polyethylene bag to prevent moisture absorption and blocking during shipping. The bobbin was then unwound and the sheet cut into strips (25-20 cuts per square inch).

[0180] Aerosol-Forming Agent Substrate 2B (Substrate of the Invention) Aerosol-forming Substrate 2B was prepared similarly to Substrate 2A, except that glycerol was replaced with a 75 / 25 mixture by weight of glycerol and propylene glycol, and zero-freeness pre-refined wood pulp was added to the hydrated alginate and mixed for 30 minutes before adding to the calcium carbonate slurry. The total batch weight was 500 lb. (See Table 2).

[0181] Aerosol-Forming Agent Substrate 2C (Substrate of the Invention) Aerosol-forming Substrate 2C was prepared similarly to Substrate 2A, except that the glycerol was replaced with a 50 / 50 mixture by weight of glycerol and propylene glycol. The total batch weight was 300 lb.

[0182] Aerosol-Forming Agent Substrate 2D (Substrate of the Invention) Aerosol-forming Substrate 2D was prepared similarly to Substrate 2A, except that the glycerol was replaced with a 25 / 75 by weight mixture of glycerol and propylene glycol. The total batch weight was 300 lb.

[0183] Aerosol former substrate 2E (reference substrate) Aerosol-forming Substrate 2E was prepared similarly to Substrate 2A, except glycerol was replaced with propylene glycol. The total batch weight was 300 lb.

[0184] Aerosol former substrate 2F (reference substrate) Aerosol-forming substrate 2F was prepared similarly to substrate 2A, except that sodium alginate was replaced with ammonium alginate as the binder.

[0185] [Table 2]

[0186] Example 3: Preparation of bead and granular rod HNB aerosol-forming substrates Aerosol former substrate 3A (reference substrate) Measured amounts of calcium carbonate (35 lb) and pregelatinized rice starch (5 lb) were added to an FM 130 D Littleford model precision plow mixer. The contents were mixed at 100 rpm for 10 minutes, then glycerol (20 lb) was added and mixed for an additional 10 minutes at 100 rpm. The mixer was stopped, and a pre-prepared carboxymethylcellulose (CMC) slurry, prepared by hydrating carboxymethylcellulose (5 lb) with water (17 lb) in a vessel using a pitchfork propeller for 30 minutes, was added and mixed at 100 rpm for 20 minutes. The contents of the plow mixer were dispensed and transferred to an MG-55-1 Fuji Paudel model multigrain extruder. The mass was extruded through a 2-3 mm dome screen die to produce multigrain (hairlike) shaped rods. The rods were then transferred to a QJ-230T-2 Fuji Paudel model laboratory mulmerizer. The rods were reformed into rounded or spheronized beads using a Marumerizer rotating bowl. The beads were then transferred to a fluidized bed agglomerator (Flo-Coater, Vector) and finally dried to 10% moisture with heated air at 60-70°C. A portion of the extruded rods was also transferred and then dried using a fluidized bed agglomerator device. The total batch weight was 50 lb.

[0187] Aerosol-Forming Agent Substrate 3B (Substrate of the Invention) Aerosol-forming Substrate 3B was prepared similarly to Substrate 3A, except that the glycerol was replaced with a 75 / 25 by weight mixture of glycerol and propylene glycol. The total batch weight was 50 lb. See Table 3.

[0188] Aerosol-Forming Agent Substrate 3C (Substrate of the Invention) Aerosol-forming Substrate 3C was prepared similarly to Substrate 3A, except that the glycerol was replaced with a 50 / 50 mixture by weight of glycerol and propylene glycol. The total batch weight was 50 lb.

[0189] Aerosol-Forming Agent Substrate 3D (Substrate of the Invention) Aerosol-forming Substrate 3D was prepared similarly to Substrate 3A, except that the glycerol / propylene glycol ratio was a 25 / 75 mixture by weight. The total batch weight was 50 lb.

[0190] Aerosol former substrate 3E (reference substrate) Aerosol-forming Substrate 3E was prepared similarly to Substrate 3A, except glycerol was replaced with propylene glycol. The total batch weight was 50 lb. See Table 3.

[0191] Aerosol former substrate 3F (reference substrate) Aerosol former Base 3F was prepared similar to Base 3A, except that rice starch was replaced with finely ground tobacco. The total batch weight was 50 lb.

[0192] [Table 3]

[0193] Example 4: Preparation of an extruded HNB aerosol former substrate Aerosol former substrate 4A (reference substrate) Hydroxypropylmethylcellulose (HPMC; 2.5 lb) and hydroxypropylcellulose (HPC; 2.5 lb) were mixed with glycerol (25 lb) in a Hobart mixer for 20 minutes. The mixture was then added to calcium carbonate (10 lb), pregelatinized rice starch (30 lb), and tobacco powder (30 lb) in an FM 130 D Littleford model precision plow mixer and mixed at 100 rpm for 30 minutes. After 30 minutes, the contents of the plow mixer were transferred in-line to a K-Tron hopper via a ZSK-25 Coperion twin-screw model extruder. The hopper contents were then fed into an extruder containing 11 barrel sections (27-100°C) operating at a screw speed of 75 rpm. Water (35 lb) was fed into the second barrel of the extruder to facilitate kneading, mixing, and plasticization of the dough. Various shapes of extrudate were produced using shaped dies (flat sheet, solid rod, rod with a center hole or internal opening, rod with a grooved outer edge). With the exception of flat sheet extrudate, the resulting extrudate was cut upon exiting the die and immediately dried to 10-12% moisture using an infrared tunnel dryer (Model Proj 0115 Glenroe Integrated Energy Delivery Systems). Total batch weight was 100 lb.

[0194] Aerosol-Forming Agent Substrate 4B (Substrate of the Invention) Aerosol-forming Substrate 4B was prepared similarly to Substrate 4A, except that the glycerol was replaced with a 50 / 50 mixture by weight of glycerol and propylene glycol. The total batch weight was 50 lb.

[0195] Aerosol-Forming Agent Substrate 4C (Substrate of the Invention) Aerosol former Base 4C was prepared similarly to Base 4B, except that the glycerol / propylene glycol ratio was a 25 / 75 mixture by weight, the amounts of rice starch, HPMC, and HPC were reduced, and liquid mint flavor was added to the glycerol / propylene glycol mixture to impart flavor to the formulation. The total batch weight was 50 lb.

[0196] [Table 4]

[0197] Example 5: DSC of aerosol-forming materials Several embodiments of liquid aerosol-forming materials and mixtures containing glycerol or propylene glycol (reference) and mixtures thereof in different ratios (invention) were prepared. The thermal properties of these embodiments were measured by differential scanning calorimetry (DSC). DSC measures the amount of energy absorbed (enthalpy) or heat required (heat of vaporization) and the amount of energy released (heat value) when an aerosol-forming agent changes phase (liquid to vapor) during heating. The results of these experiments (Table 5 and Figure 7) showed that when propylene glycol (PG) was mixed with glycerol (VG) at levels >50%, less heat or energy was required to change the aerosol-forming material from liquid to aerosol (endotherm). The latter indicates that combining aerosol-forming materials with different boiling points or vapor pressures can lead to aerosol formation over a wider temperature range than each of the individual components.

[0198] [Table 5]

[0199] Example 6: DSC of aerosol-generating components The thermal profiles of embodiments of the aerosol-generating component within the substrate matrix were measured by DSC. A similar trend in the decrease in endothermic enthalpy with increasing PG content in the liquid mixture was observed across the evaluated examples (Table 6). In general, increasing the ratio of PG to glycerol (>50%) reduces the enthalpy or heat of vaporization in any matrix (paper recon, cast sheet, or beaded product). The data in Table 6 also revealed that aerosol formation was affected by the matrix format, e.g., a lower enthalpy for beaded products.

[0200] [Table 6]

[0201] Example 7: Thermogravimetric Analysis Mass Spectrometry (TGA / MS) Ion Curves for Aerosol-Generating Components in a Substrate Matrix The ion curve profiles of embodiments of the aerosol-generating component within a substrate matrix were measured by TGA / MS. The substrate samples were heated from ambient temperature to 250°C (1 minute) and then held at 250°C for 4 minutes. Figure 8 (overlay of ion current curve for glycerol (M / Z 43); paper reconstitution treated substrate) and Figure 9 (ion current curve for glycerol (M / Z 43)); bead substrate) show a broader aerosolized glycerol ion curve distribution over time for the mixed glycerol-PG sample when compared to the glycerol or PG-only counterparts. These observations demonstrate the benefits of using a mixture of two or more aerosol-forming materials with one aerosol-forming material over a period of time for aerosol formation.

Claims

1. An aerosol generating member comprising a substrate impregnated with two or more aerosol-forming materials, including a first aerosol-forming material and a second aerosol-forming material, wherein the first aerosol-forming material and the second aerosol-forming material each have different boiling points, different vapor pressures, or both.

2. The aerosol generating member according to 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, triacetin, waxes, cannabinoids, terpenes, and sugar alcohols.

3. The aerosol generating member according to claim 1 or 2, wherein two or more aerosol-forming materials are present in a weight ratio of approximately 3:1 to approximately 1:3 between the first aerosol-forming material and the second aerosol-forming material.

4. The aerosol generating member according to any one of claims 1 to 3, wherein at least one of the first aerosol-forming material and the second aerosol-forming material is a polyhydric alcohol.

5. The aerosol generating member according to any one of claims 1 to 3, wherein both the first aerosol-forming material and the second aerosol-forming material are polyhydric alcohols.

6. The aerosol generating member according to claim 5, wherein the polyhydric alcohol is selected from the group consisting of glycerol, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, and combinations thereof.

7. The aerosol generating member according to claim 5, wherein the polyhydric alcohol is glycerol and propylene glycol.

8. The aerosol generating member according to claim 7, wherein glycerol and propylene glycol are present in a weight ratio of about 3:1 to about 1:

3.

9. The aerosol generating member according to claim 7, wherein glycerol and propylene glycol are present in a weight ratio of about 1:

1.

10. The aerosol generating member according to any one of claims 1 to 9, wherein the base material is further impregnated with at least one additional aerosol-forming agent.

11. The aerosol generating member according to claim 10, wherein at least one additional aerosol-forming agent is selected from the group consisting of water, polysorbate, sorbitan ester, fatty acid, fatty acid ester, triacetin, wax, sugar alcohol, cannabinoid, terpene, and combinations thereof.

12. The aerosol generating member according to any one of claims 1 to 11, wherein the base material is further impregnated with a flavoring agent, an active ingredient, or a combination thereof.

13. The aerosol generating member according to claim 12, wherein the active ingredient comprises a tobacco component, a non-tobacco botanical component, a nicotine component, or a combination thereof.

14. The aerosol generating member according to claim 12, wherein the active ingredient contains a nicotine component.

15. The aerosol generating member according to any one of claims 1 to 14, wherein the base material is impregnated with two or more aerosol-forming materials at a loading amount of approximately 15 to approximately 55% by weight, based on the total weight of the impregnated base material.

16. The aerosol generating member according to any one of claims 1 to 15, wherein the base material is in the form of particulate matter, shredded material, film, paper process sheet, cast sheet, beads, granular rod, or extruded product.

17. The aerosol generating member according to claim 16, wherein the base material is formed in a substantially cylindrical shape.

18. The aerosol generating member according to any one of claims 1 to 17, wherein the base material includes tobacco-derived fibers, wood-derived fibers, or a combination thereof.

19. The aerosol generating member according to claim 18, wherein the base material further comprises one or more binders.

20. The aerosol generating member according to claim 19, wherein one or more binders are selected from alginate, cellulose derivatives, starch, gum, dextran, carrageenan, calcium carbonate, or a combination thereof.

21. The aerosol generating member according to any one of claims 1 to 17, wherein the base material comprises one or more of the following: calcium carbonate, alginate, one or more cellulose derivatives, starch, wood pulp, or tobacco-derived fibers.

22. The aerosol generating member according to claim 21, wherein two or more aerosol-forming materials are present in a weight ratio of approximately 3:1 to approximately 1:

3.

23. The aerosol generating member according to claim 22, wherein two or more aerosol-forming materials are glycerol and propylene glycol.

24. The base material is Approximately 0 to 5% by weight of calcium carbonate, Approximately 1% to 5% by weight of wood pulp, Approximately 70-80% by weight of tobacco-derived fibers Includes, The substrate is impregnated with two or more aerosol-forming materials at a loading amount of approximately 15 to 25% by weight, based on the total weight of the impregnated substrate. The aerosol generating member according to claim 1.

25. The base material is Approximately 45 to 60% by weight of calcium carbonate, Approximately 0 to approximately 10% by weight of alginate, Approximately 0 to approximately 5% by weight of one or more cellulose derivatives, Approximately 0 to 15% by weight of starch, Approximately 0 to 5% by weight of wood pulp, Approximately 0 to 40% by weight of tobacco-derived fibers Includes, The substrate is impregnated with two or more types of aerosol-forming materials at a loading amount of approximately 15 to 25% by weight, based on the total weight of the impregnated substrate. The aerosol generating member according to claim 1.

26. The base material is Approximately 40 to 60% by weight of calcium carbonate, Approximately 0 to approximately 10% by weight of alginate, Approximately 0 to approximately 5% by weight of one or more cellulose derivatives, Approximately 0 to 15% by weight of starch, Approximately 0 to 5% by weight of wood pulp, Approximately 0 to 40% by weight of tobacco-derived fibers Includes, The substrate is impregnated with two or more aerosol-forming materials at a loading amount of approximately 15 to 25% by weight, based on the total weight of the impregnated substrate. The aerosol generating member according to claim 1.

27. The base material is Approximately 5 to 15% by weight of calcium carbonate, Approximately 1 to 5% by weight of one or more cellulose derivatives, Approximately 20 to 40% by weight of starch, Approximately 20-40% by weight of tobacco-derived fibers Includes, The substrate is impregnated with two or more aerosol-forming materials at a loading amount of approximately 15 to 25% by weight, based on the total weight of the impregnated substrate. The aerosol generating member according to claim 1.

28. Aerosol generating member according to any one of claims 1 to 27, A heat source configured to heat an impregnated substrate in order to form an aerosol, and Aerosol pathway extending from the aerosol generating component to the mouse end of the aerosol delivery device. Aerosol delivery devices, including those mentioned above.

29. The aerosol delivery device according to claim 28, wherein the heat source includes either an electric heating element or a flammable ignition source.

30. The aerosol delivery device according to claim 28, wherein the heat source is a flammable ignition source containing a carbon-based material.

31. The aerosol delivery device according to claim 28, wherein the heat source is an electric heating element.

32. The aerosol delivery device according to claim 31, further comprising a power supply electrically connected to a heating element.

33. The aerosol delivery device according to claim 31, further comprising a controller configured to control the power transmitted to the heating element by a power source.

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