Capsule-containing aerosol-generating substrate for an aerosol delivery device - Patent Application 20070122997

Abstract

The present disclosure provides a substrate comprising a filler, e.g., tobacco or non-tobacco botanical material, a binder, an aerosol-forming material, and a capsule, wherein the capsule comprises an inner payload of the aerosol-forming material, an active ingredient, a flavoring substance, or a combination thereof. The final form of the substrate can be configured for use in an aerosol generating element for an aerosol delivery device. Aerosol generating elements and aerosol delivery devices comprising the substrate are also provided. Such devices utilize an electrical heating or combustible ignition source to heat the substrate, thereby producing an inhalable substance in aerosol form.

Description

[Technical Field]

[0001] The present disclosure relates to an aerosol delivery system that utilizes an aerosol generating element, an aerosol delivery device, and an electrical heat or combustible ignition source to heat the aerosol-forming material, thereby providing an inhalable substance in aerosol form for human consumption, generally without significant combustion. [Background technology]

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

[0003] The focus of improvement or replacement for aerosol-producing products 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 achieve this goal, many smoking products, flavor generating devices, and medicinal inhalers have been proposed that utilize electrical energy to vaporize or heat volatile materials, or have attempted to provide the sensations of cigarette, cigar, or pipe smoking without burning tobacco to a significant extent. See, for example, the various alternative smoking articles, aerosol delivery devices, and heat-generating sources described in the background art of Robinson et al., U.S. Pat. No. 7,726,320; Griffith, Jr. et al., U.S. Patent Application Publication No. 2013 / 0255702; and Sears et al., U.S. Patent Application Publication No. 2014 / 0096781, each of which is incorporated herein by reference in its entirety. [Prior art documents] [Patent documents]

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

[0005] Articles that produce the taste and sensation of smoking by electrically heating tobacco, tobacco-derived materials, or other plant-derived materials have suffered from inconsistent performance characteristics. For example, some articles suffer from inconsistent release of flavor or other inhalable substances, insufficient loading of the aerosol-forming material onto the substrate, or poor sensory properties. [Means for solving the problem]

[0006] (Summary of the Invention) The present disclosure relates to a substrate for use in an aerosol delivery device, which provides an inhalable substance in aerosol form for human consumption by heating the substrate using an electrical heat source or a combustible ignition source. Thus, in one aspect, the present disclosure provides a substrate for use in an aerosol delivery device, which generally comprises tobacco or non-tobacco botanical materials or other filler components; one or more binders; an aerosol-forming material; and one or more capsules. The presence of one or more capsules in such a substrate can provide certain benefits in certain embodiments, such as increasing the substrate's ability to retain one or more useful ingredients / additives, such as flavor substances or aerosol-forming materials. Furthermore, encapsulation of certain volatile flavor substances or other ingredients can enhance the stability of the ingredients and preserve the ingredients in the substrate until the substrate is used for aerosol delivery.

[0007] In some embodiments, an aerosol-generating substrate for use in an aerosol delivery device comprises tobacco or non-tobacco botanical material, one or more binders, one or more aerosol-forming materials, and one or more capsules. In some embodiments, each of the one or more capsules comprises a degradable outer shell or polymer matrix. In some embodiments, the outer shell or polymer matrix encapsulates an inner payload. In some embodiments, the substrate further comprises a stabilizer fixedly affixed to the outer shell of the capsule.

[0008] In some embodiments, the inner payload comprises an aerosol-forming material, an active ingredient, a flavoring substance, or a combination thereof.

[0009] In some embodiments, the active ingredient is selected from the group consisting of a nicotine component, a botanical material, a stimulant, an amino acid, a vitamin, an antioxidant, a dietary supplement, a cannabinoid, a cannabimimetic, a terpene, a pharmaceutical, and combinations thereof.

[0010] In some embodiments, the tobacco or non-tobacco botanical material is present in shredded, granular, or particulate form.

[0011] In some embodiments, the outer shell of each of the one or more capsules is degradable upon exposure to heat. In some embodiments, the outer shell of each of the one or more capsules is degradable upon exposure to moisture. In some embodiments, the outer shell of each of the one or more capsules is degradable upon exposure to enzymes. In some embodiments, the outer shell of each of the one or more capsules is degradable and is comprised of a body and a stabilizer.

[0012] In some embodiments, the aerosol-forming material is present in an amount of about 10% by weight or greater, based on the total dry weight of the substrate. In some embodiments, the aerosol-forming material is present in an amount of about 20% by weight or greater, based on the total dry weight of the substrate. In some embodiments, the aerosol-forming material is present in an amount ranging from about 10 to about 70% by weight. In some embodiments, the aerosol-forming material is present in an amount ranging from about 30 to about 60% by weight.

[0013] In some embodiments, the aerosol-forming material is selected from the group consisting of water, polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, non-fatty acid esters, waxes, cannabinoids, terpenes, sugar alcohols, and combinations thereof. In some embodiments, the aerosol-forming material is a polyhydric alcohol. In some embodiments, the polyhydric alcohol is selected from the group consisting of glycerol, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, and combinations thereof. In some embodiments, the aerosol-forming material is glycerol.

[0014] In some embodiments, the substrate is in the form of a sheet.

[0015] In some embodiments, the outer shell or polymer matrix comprises a polymer selected from the group consisting of gelatin, genipin-crosslinked gelatin, polyhydroxyalkanoate (PHA), polycaprolactone (PCL), pullulan, glucan, chitosan, ethylcellulose, and combinations thereof.

[0016] In some embodiments, the thermal decomposition temperature of the outer wall or polymer matrix is ​​at least about 250°C. In some embodiments, the thermal decomposition temperature of the outer wall or polymer matrix is ​​at least about 275°C. In some embodiments, the thermal decomposition temperature of the outer wall or polymer matrix is ​​at least about 300°C. In some embodiments, the thermal decomposition temperature of the outer wall or polymer matrix is ​​at least 325°C. In some embodiments, the thermal decomposition temperature of the outer wall or polymer matrix is ​​from about 250°C to about 400°C.

[0017] In some embodiments, the melting point of the outer wall or polymer matrix is ​​at least about 100°C. In some embodiments, the melting point of the outer wall or polymer matrix is ​​at least about 125°C. In some embodiments, the melting point of the outer wall or polymer matrix is ​​at least about 150°C. In some embodiments, the melting point of the outer wall or polymer matrix is ​​at least about 200°C. In some embodiments, the melting point of the outer wall or polymer matrix is ​​from about 100°C to about 350°C.

[0018] In some embodiments, the aerosol generating element comprises a substrate of any of the embodiments disclosed above. In some embodiments, the aerosol generating element further comprises a support. In some embodiments, the substrate is affixed to the support. In some embodiments, the support is planar.

[0019] In some embodiments, the aerosol delivery device includes the aerosol delivery device disclosed above and a heat source. In some embodiments, the heat source is configured to heat the aerosol generating element to form an aerosol. In some embodiments, the aerosol pathway extends from the aerosol generating element and along a length configured to convey the aerosol to the mouth of the aerosol delivery device.

[0020] In some embodiments, the heat source comprises 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.

[0021] In some embodiments, the aerosol delivery device further comprises a power source electronically connected to the heating element.

[0022] In some embodiments, the aerosol delivery device further comprises a controller, hi some embodiments, the controller is configured to control the power delivered to the heating element by the power source.

[0023] In some embodiments, the heat source is a conductive heat source. In some embodiments, the heat source is an inductive heat source.

[0024] The present disclosure includes, without limitation, the following embodiments. Embodiment 1: An aerosol-generating substrate for use in an aerosol delivery device, comprising: A substrate comprising: a filler (e.g., a cellulosic material, a starch, a sugar, or a combination thereof); one or more binders; one or more aerosol-forming materials; and one or more capsules, each of the one or more capsules comprising a degradable outer shell or polymer matrix, the outer shell or polymer matrix encapsulating an inner payload.

[0025] Embodiment 2: The substrate of embodiment 1, wherein one or more capsules comprise a stabilizer fixedly affixed to the outer shell or polymer matrix of the capsule.

[0026] Embodiment 3: The substrate of embodiment 1 or 2, wherein the inner payload comprises an aerosol-forming material, an active ingredient, a flavoring substance, or a combination thereof.

[0027] Embodiment 4: The substrate of embodiment 3, wherein the active ingredient is selected from the group consisting of a nicotine component, a botanical material, a stimulant, an amino acid, a vitamin, an antioxidant, a dietary supplement, a cannabinoid, a cannabimimetic, a terpene, a pharmaceutical, and combinations thereof.

[0028] Embodiment 5: The substrate of any one of embodiments 1-4, wherein the filler comprises tobacco or non-tobacco botanical material present in flake, granular, or particulate form.

[0029] Embodiment 6: The substrate of any one of embodiments 1-5, wherein the outer shell of each of the one or more capsules is degradable upon exposure to heat.

[0030] Embodiment 7: The substrate of any one of embodiments 1-6, wherein the outer shell or polymer matrix of each of the one or more capsules is degradable upon exposure to moisture.

[0031] Embodiment 8: The substrate of any one of embodiments 1-7, wherein the outer shell or polymer matrix of each of the one or more capsules is degradable upon exposure to an enzyme.

[0032] Embodiment 9: The substrate of any one of embodiments 1 to 8, wherein the outer shell or polymer matrix of each of the one or more capsules is degradable and is composed of a body and a stabilizer.

[0033] Embodiment 10: The substrate of any one of embodiments 1-9, wherein the aerosol-forming material is present in an amount of about 10% by weight or greater, based on the total dry weight of the substrate.

[0034] Embodiment 11: The substrate of any one of embodiments 1-10, wherein the aerosol-forming material is present in an amount of about 20% by weight or greater, based on the total dry weight of the substrate.

[0035] Embodiment 12: The substrate of any one of embodiments 1 to 11, wherein the aerosol-forming material is present in an amount ranging from about 10 to about 70% by weight.

[0036] Embodiment 13: The substrate of any one of embodiments 1 to 12, wherein the aerosol-forming material is present in an amount ranging from about 30 to about 60% by weight.

[0037] Embodiment 14: The substrate of any one of embodiments 1-13, wherein the aerosol-forming material is selected from the group consisting of water, polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, non-fatty acid esters, waxes, cannabinoids, terpenes, sugar alcohols, and combinations thereof.

[0038] Embodiment 15: The substrate of any one of embodiments 1-14, wherein the aerosol-forming material is a polyhydric alcohol.

[0039] Embodiment 16: The substrate of any one of embodiments 1-15, wherein the polyhydric alcohol is selected from the group consisting of glycerol, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, and combinations thereof.

[0040] Embodiment 17: The substrate of any one of embodiments 1-16, wherein the aerosol-forming material is glycerol.

[0041] Embodiment 18: The substrate of any one of embodiments 1 to 17, wherein the substrate has a form selected from the group consisting of particles, granules, pellets, flakes, strips, sheets, and films.

[0042] Embodiment 19: The substrate of any one of embodiments 1 to 18, wherein the outer shell or polymer matrix of one or more capsules comprises a polymer selected from the group consisting of gelatin, genipin-crosslinked gelatin, polyhydroxyalkanoate (PHA), polycaprolactone (PCL), pullulan, glucan, chitosan, ethylcellulose, and combinations thereof.

[0043] Embodiment 20: The substrate of any one of embodiments 1-19, wherein the outer wall or polymer matrix has a thermal decomposition temperature of at least about 250°C.

[0044] Embodiment 21: The substrate of any one of embodiments 1-20, wherein the thermal decomposition temperature of the outer shell or polymer matrix of the one or more capsules is at least about 275°C.

[0045] Embodiment 22: The substrate of any one of embodiments 1 to 21, wherein the outer shell or polymer matrix of the one or more capsules has a thermal decomposition temperature of at least about 300°C.

[0046] Embodiment 23: The substrate of any one of embodiments 1 to 22, wherein the outer shell or polymer matrix of one or more capsules has a thermal decomposition temperature of at least 325°C.

[0047] Embodiment 24: The substrate of any one of embodiments 1 to 23, wherein the outer wall or polymer matrix has a thermal decomposition temperature of from about 250°C to about 400°C.

[0048] Embodiment 25: The substrate of any one of embodiments 1 to 24, wherein the outer shell or polymer matrix of the one or more capsules has a melting point of at least about 100°C.

[0049] Embodiment 26: The substrate of any one of embodiments 1 to 25, wherein the outer shell or polymer matrix of the one or more capsules has a melting point of at least about 125°C.

[0050] Embodiment 27: The substrate of any one of embodiments 1 to 26, wherein the outer shell or polymer matrix of the one or more capsules has a melting point of at least about 150°C.

[0051] Embodiment 28: The substrate of any one of embodiments 1 to 27, wherein the outer shell or polymer matrix of one or more capsules has a melting point of at least about 200°C.

[0052] Embodiment 29: The substrate of any one of embodiments 1 to 28, wherein the melting point of the outer shell or polymer matrix of the one or more capsules is from about 100°C to about 350°C.

[0053] Embodiment 30: An aerosol generating element for use with an aerosol delivery device, the aerosol generating element comprising the substrate of any one of embodiments 1 to 29.

[0054] Embodiment 31: The aerosol generating element of embodiment 30, further comprising a support, the substrate being attached to the support.

[0055] Embodiment 32: The aerosol-generating element of embodiment 31, wherein the support is planar.

[0056] Embodiment 33: An aerosol delivery device comprising: an aerosol generation element of any one of embodiments 30 to 32; a heat source configured to heat the aerosol generation element to form an aerosol; and an aerosol path extending from the aerosol generation element and extending along a length configured to convey the aerosol to the mouth of the aerosol delivery device.

[0057] Embodiment 34: The aerosol delivery device of embodiment 33, wherein the heat source comprises an electric heating element or a combustible ignition source.

[0058] Embodiment 35: The aerosol delivery device of embodiment 33, wherein the heat source is a combustible ignition source comprising a carbon-based material.

[0059] Embodiment 36: The aerosol delivery device of embodiment 33, wherein the heat source is an electric heating element.

[0060] Embodiment 37: The aerosol delivery device of any one of embodiments 33 to 36, further comprising a power source electronically connected to the heating element.

[0061] Embodiment 38: The aerosol delivery device of embodiment 37, further comprising a controller configured to control the power delivered by the power source to the heating element.

[0062] Embodiment 39: The aerosol delivery device of embodiment 33, wherein the heat source is a conductive heat source or an inductive heat source.

[0063] These and other features, aspects, and advantages of the present disclosure will become apparent from the following detailed description read in conjunction with the accompanying figures, which are briefly described below. The present disclosure includes combinations of any two, three, four, or more features or elements described in this disclosure, regardless of whether such features or elements are explicitly combined or otherwise set forth in the implementation of a particular embodiment described herein. The present disclosure is intended to be read as a whole, whereby any separable features or elements of the disclosure should be considered combinable in any of its various aspects and implementations, unless the context of the disclosure clearly dictates otherwise.

[0064]

[0013] Accordingly, it will be appreciated that this brief summary is provided merely for the purpose of summarizing some exemplary implementations so as to provide a basic understanding of some aspects of the present disclosure. Accordingly, it will be appreciated that the above exemplary implementations are merely examples and should not be construed in any way as narrowing the scope or spirit of the present disclosure. Other exemplary implementations, aspects, and advantages will become apparent from the following detailed description, taken in conjunction with the accompanying figures which illustrate, by way of example, the principles of some described exemplary implementations.

[0065] Having thus described aspects of the present disclosure in the foregoing general terms, reference is now made to the accompanying figures, which are not necessarily drawn to scale and are illustrative only and should not be construed as limiting the disclosure. [Brief explanation of the drawings]

[0066] [Figure 1] 1 illustrates a schematic cross-sectional view of an aerosol-generating element including a support and a substrate. [Figure 2] 1 illustrates a perspective view of an aerosol delivery device including a controller and an aerosol generating element, the aerosol generating element and the controller being connected to each other, according to an exemplary embodiment of the present disclosure; [Figure 3] 3 illustrates a perspective view of the aerosol delivery device of FIG. 2, in which the aerosol generation element and the control device are separated from each other, according to an exemplary embodiment of the present disclosure. [Figure 4] 1 illustrates a schematic perspective view of an aerosol generation element according to an exemplary embodiment of the present disclosure. [Figure 5] 1 illustrates a perspective view of an aerosol generation element according to an exemplary embodiment of the present disclosure. [Figure 6] 6 illustrates a perspective view of the aerosol generating element of FIG. 5 with outer packaging removed, according to an exemplary embodiment of the present disclosure. [Figure 7] 1 illustrates a schematic cross-sectional view of a substrate portion of an aerosol generating element according to an exemplary embodiment of the present disclosure. [Figure 8] 1 illustrates a schematic cross-sectional view of an aerosol generation element according to an exemplary embodiment of the present disclosure. [Figure 9] 1 illustrates a top view of a capsule according to an exemplary embodiment of the present disclosure. [Figure 10] 10 illustrates a perspective view of the capsule of FIG. 9 according to an exemplary embodiment of the present disclosure. [Figure 11] 10 illustrates a side view of the capsule of FIG. 9 according to an exemplary embodiment of the present disclosure. [Figure 12] 1 illustrates a schematic cross-sectional view of a capsule according to an exemplary embodiment of the present disclosure. [Figure 13] 1 illustrates a schematic cross-sectional view of a capsule according to an exemplary embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0067] The present disclosure will now be described more fully hereinafter with reference to exemplary embodiments thereof. These exemplary embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Indeed, the disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will meet applicable legitimate requirements.

[0068] As used in this specification and the claims, the singular forms "a," "an," and "the" include plural references unless such context clearly dictates otherwise.

[0069] The term "about" is used throughout this specification to describe and clarify small variations. For example, the term "about" can refer to ±10% or less, for example, ±5% or less, ±2% or less, ±1% or less, ±0.5% or less, ±0.2% or less, ±0.1% or less, or ±0.05% or less. All numerical values ​​in this specification are modified by the term "about," whether or not explicitly indicated. Values ​​modified by the term "about" of course include the specific value. For example, "about 5.0" must include 5.0.

[0070] References to percentages are intended to mean weight percent unless otherwise indicated. All weight percentages set forth herein are calculated on a dry weight basis unless expressly stated. References to "dry weight percent" or "dry weight basis" refer to weights based on dry components (i.e., all components excluding water). Weights given on a dry weight basis refer to the totality of slurries, materials, etc., other than water or other solvents, and may include components that are liquid by themselves at room temperature and pressure, such as glycerol or other aerosol-forming materials. Conversely, weight percentages given on a wet weight basis refer to all components, including water or other solvents.

[0071] Base material As described hereinafter, exemplary embodiments of the present disclosure relate to substrates for use in aerosol delivery devices. The substrates can include a variety of materials, alone or in combination. The substrates of the present disclosure generally include a filler, which can include tobacco or non-tobacco botanical materials. In certain embodiments, one or more additional fillers can be used in combination with or in place of the tobacco or non-tobacco botanical materials. The substrates according to the present disclosure can further include a binder, an aerosol-forming material, and one or more capsules having an inner payload. Each of the substrate elements is further described herein below.

[0072] Filler The substrates disclosed herein optionally include a filler in addition to or in place of the tobacco material. The filler can include materials such as non-tobacco botanical materials, cellulosic materials, wood fibers or pulp, starch, sugars, sugar alcohols, inorganic substances, inert materials, and the like, and combinations thereof. The amount of filler can vary. In some embodiments, the substrate includes up to about 70% by dry weight of filler, based on the total dry weight of the substrate. For example, in some embodiments, the substrate includes about 30% to about 70% by weight of filler, based on the total dry weight of the substrate. More than one filler may be used. In such embodiments, it is understood that references to weight percent filler are intended to reflect the total amount of the combination of fillers present in the substrate.

[0073] Microcrystalline cellulose In some embodiments, microcrystalline cellulose ("mcc") is used as a filler in the substrate. In addition to functioning as a filler, the microcrystalline cellulose material used herein can, in certain embodiments, serve as a carrier, for example, for flavor substances. Microcrystalline cellulose has numerous uses, for example, as a conditioner, anticaking agent, fat substitute, emulsifier, bulking agent, and swelling agent, as well as an excipient for direct compression, binder, disintegrant, absorbent, filler, diluent, lubricant, and anti-adhesive. In contrast to other cellulosic materials obtained directly from pulp, microcrystalline cellulose is a refined pulp product. While pulp is a lignocellulosic fibrous material prepared by chemically or mechanically separating cellulose fibers from wood, fiber crops, waste paper, or rags, microcrystalline cellulose is distinguished as refined, partially depolymerized cellulose.

[0074] Cellulose is a naturally occurring polymer composed of glucose units connected by 1-4 beta-glycosidic bonds. Linear chains of cellulose are bundled together as microfibrils in the walls of plant cells. Each microfibril defines a crystalline structure that is insoluble in water and resistant to chemicals. However, the microfibrils contain amorphous regions with weaker internal bonds. The crystalline structures are isolated to produce microcrystalline cellulose. Microcrystalline cellulose can be produced solely from alpha cellulose (also known as "chemical cellulose"), a highly purified, insoluble, relatively high-molecular-weight cellulose from which sugars, pectins, and other soluble materials have been removed. With respect to other types of cellulose, beta cellulose is defined as a more degraded form of cellulose with fewer crystalline regions. Furthermore, gamma cellulose is defined as a short-chain hemicellulose. Therefore, beta cellulose and gamma cellulose are typically removed from the inputs used to produce microcrystalline cellulose.

[0075] To produce microcrystalline cellulose, alpha cellulose can be first shredded and then immersed in a warm bath of mineral acid to dissolve the amorphous regions of the microfibrils while leaving the microcrystalline structure intact. The microcrystalline structure can then be subjected to hydrolysis to break down the long polymer chains until the degree of polymerization decreases and levels off at the desired scale. Chemicals and impurities can then be removed via water washing, followed by drying. The resulting microcrystalline cellulose can be embodied as a fine, white, crystallized powder in a raw form. Methods for forming microcrystalline cellulose from plant materials are described, for example, in U.S. Patent No. 9,339,058 to Byrd, Jr. et al. and U.S. Patent No. 10,774,472 to Sebastian et al., both of which are incorporated herein by reference in their entireties. MCC materials are commercially available from suppliers such as DuPont de Nemours, Inc., Asahi Kasei Corporation, Sigachi Industries Limited, Accent Microcell Pvt. Ltd., and DFE Pharma GmbH & Co. KG. The microcrystalline cellulose may be selected from the group consisting of AVICEL® grades PH-100, PH-102, PH-103, PH-105, PH-112, PH-113, PH-200, PH-300, PH-302, VIVACEL® grades 101, 102, 12, 20, and EMOCEL® grades 50M and 90M, and mixtures thereof.

[0076] Microcrystalline cellulose is typically used in particulate form, and particle size can vary.In certain embodiments, microcrystalline cellulose material is in the form of very fine particulate form, for example, particles with a D90 particle size of about 250 microns or less, for example, about 170 microns or less or about 150 microns or less.As used herein, the term "D90 particle size" means that 90% of all particles are smaller than a given size.Particle size can be measured, for example, by laser diffraction or using a particle size analyzer.

[0077] In certain embodiments, microcrystalline cellulose materials have a relatively low bulk density compared to other types of cellulose materials, which is advantageous when a material with a higher loading value is desired. Exemplary ranges of bulk density for microcrystalline cellulose materials used in the present disclosure are about 0.50 g / mL or less, e.g., about 0.26 to about 0.35 g / mL or about 0.26 to about 0.5 g / mL, as determined by measuring the volume of a powder of known mass.

[0078] In some embodiments, microcrystalline cellulose can advantageously provide one or more of improved texture, caking, and anti-adhesion properties to substrates comprising microcrystalline cellulose, compared to other cellulosic materials.

[0079] The amount of microcrystalline cellulose present in the substrate may vary. In some embodiments, the substrate comprises, on a dry weight basis, about 25% or more microcrystalline cellulose, e.g., about 25 to about 60% microcrystalline cellulose, about 30 to about 55% or about 35 to about 50% microcrystalline cellulose, on a dry weight basis. In some embodiments, the substrate comprises, on a dry weight basis, about 25, about 30, about 35, about 40, or about 45 to about 50% microcrystalline cellulose, about 55% or about 60% microcrystalline cellulose.

[0080] Other cellulosic materials In some embodiments, the filler comprises additional cellulosic materials, such as cellulosic materials derived from flax, cotton linters, kenaf, hibiscus, hemp, tobacco, sisal, rice straw, or esparto. Other suitable cellulosic materials include, but are not limited to, cereal grains (e.g., corn, oat, barley, rye, buckwheat, etc.), sugar beet (e.g., FIBREX® brand filler available from International Fiber Corporation), bran fiber, and mixtures thereof.

[0081] In some embodiments, the cellulosic material is a cellulosic pulp or regenerated cellulose comprising at least about 90% cellulose by weight, e.g., about 90%, about 95%, about 99%, or even 100% cellulose by weight. "Regenerated cellulose" refers to natural cellulose that has been regenerated by conversion to a soluble or soluble cellulosic derivative and subsequently formed into fibers, typically via polymer spinning or film polymer casting, precipitation, or extrusion.

[0082] In some embodiments, the cellulosic material comprises a nanocellulose material. As used herein, "nanocellulose material" refers to a cellulosic material having at least one average particle size dimension in the range of about 1 nm to about 100 nm. As a non-limiting example, a suitable nanocellulose material is a fibrous material prepared from any suitable cellulose-containing material, such as grass (e.g., bamboo), cotton, tobacco, algae, and other plant-based materials, where the fibers are further refined to produce nanofibrillated cellulose fibers.

[0083] wood fiber In some embodiments, the filler comprises wood or wood-derived fibers (e.g., wood pulp). For example, in some embodiments, the substrate comprises, on a dry weight basis, about 0 to about 15% wood pulp, e.g., about 1% to about 15%, or about 5 to about 15% wood pulp. In some embodiments, the substrate comprises, on a dry weight basis, about 5 to about 11%, or about 5 to about 9% wood pulp, e.g., about 5, about 6, about 7, about 8, about 9, about 10, or about 11% wood pulp. The presence of wood pulp can enhance the structural integrity of the substrate sheet material.

[0084] In other embodiments, the substrate is substantially free or completely free of wood fiber or wood pulp. "Substantially free" of wood fiber or pulp means that no wood fiber or pulp has been intentionally added, beyond trace amounts that may be naturally present, for example, in botanicals or other plant materials. For example, certain embodiments may be characterized as having less than 0.1% dry weight, or less than 0.01% dry weight, or less than 0.001% dry weight, or 0% dry weight of wood fiber or pulp, based on the total dry weight of the substrate.

[0085] In some embodiments, the filler comprises a combination of microcrystalline cellulose and wood pulp. In some embodiments, the filler is a combination of microcrystalline cellulose and wood pulp.

[0086] Non-Tobacco Botanicals In some embodiments, the filler comprises a non-tobacco botanical material. As used herein, the term "botanical material" or "botanical" refers to any plant or fungal-derived material, including plant material in its natural form and plant material derived from natural plant material, such as processed plant material (e.g., plant material 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 materials," which refer to seed-bearing plants that do not produce persistent xylem tissue and are often valued for their medicinal or sensory properties (e.g., tea or tisane). Referring to botanical materials as "non-tobacco" is intended to exclude tobacco materials (i.e., not including any Nicotiana species). Botanical materials used in this disclosure may include, without limitation, any of the compounds and sources described herein, including mixtures thereof. Certain botanical materials of this type are sometimes called dietary supplements, nutraceuticals, "phytocompounds" or "functional foods."

[0087] Non-limiting examples of non-tobacco botanical materials include, without limitation, acai berry (Euterpe oleracea martius), acerola (Malpighia glabra), alfalfa, allspice, angelica root, anise (e.g., star anise), annatto seed, apple (Malus domestica), apricot oil, bacopa monniera, basil (Ocimum basilicum), bee balm, beetroot, bergamot, blackberry (Morus nigra), black cohosh, black pepper, black tea, blueberry, boldo (Peumus boldus), borage, amaryllis, cacao, calamus root, camu camu (Myrcaria dubia), dubia), hemp / marijuana, caraway seeds, catnip, catuaba, cayenne, cayenne pepper, chaga, chamomile, cherries, chervil, chocolate, cinnamon (Cinnamomum cassia), citron grass (Cymbopogon citratus), clary sage, cloves, coconut (Cocos nucifera), coffee, comfrey leaf and root, coriander seeds, cranberries, dandelions, echinacea, elderberry, elderberry, endro (Anethum graveolens), evening primrose, eucalyptus, fennel, feverfew, garlic, ginger (Zingiber officinale) officinale), Ginkgo biloba, Ginseng, Goji berry, Goldenseal, Grape seed, Grapefruit, Pink grapefruit (Citrus paradisi), Graviola (Annona muricata), Green tea, Gotu kola, Hawthorn, Hibiscus flower (Hibiscus sabdariffa),sabdariffa), honeybush, gynostemma, kava, jambu (Spilanthes oleraceae), jasmine (Jasminum officinale), juniper berry (Juniperus communis), lavender, lemon (Citrus limon), licorice, lilac, Yamabushitake mushroom, maca (Lepidium meyenii), marjoram, milk thistle, mint, oolong tea, orange (Citrus sinensis), oregano, papaya, pennyroyal, peppermint (Mentha piperita) piperita), potato peels, quince, red clover, rooibos (red or green), rosehips (Rosa canina), rosemary, sage, St. John's wort, salvia (Salvia officinalis), savory, saw palmetto, silybum marianum, slippery elm bark, high-tannin sorghum bran, high-tannin sorghum grain, spearmint (Mentha spicata), spirulina, sumac bran, thyme, turmeric, bearberry, valerian, vanilla, wild yam root, wintergreen, withania somnifera, yacon root, yellow dock, yerba mate, and yerba santa.

[0088] In some embodiments, the substrate comprises a non-tobacco material of plant origin, including, but not limited to, eucalyptus, rooibos, star anise, fennel, hemp, flax, sisal, rice straw, esparto, and combinations thereof.

[0089] The amount of non-tobacco botanical material present can vary and is generally less than about 50% by weight of the substrate, based on the total dry weight of the substrate. For example, the non-tobacco botanical material may be present in an amount of about 0%, about 0.1%, about 0.5%, about 1%, about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, or about 50% by weight of the substrate, based on the total dry weight of the substrate.

[0090] Starch and sugar In some embodiments, the filler comprises starch, including native and modified starches. Certain starch materials can also be included in the substrate as binders or other functional additives. "Starch," as used herein, can refer to pure starch from any source, modified starch, or starch derivatives. Starch is typically present in granular form in almost all green plants and in various types of plant tissues and organs (e.g., seeds, leaves, rhizomes, roots, tubers, shoots, fruits, grains, and stems). Starch can vary in composition and granular shape and size. Starches from different sources often have different chemical and physical characteristics. A particular starch can be selected for inclusion in the beads based on the starch material's ability to impart specific sensory properties to the beads. Starch from a variety of sources can be used. For example, primary sources of starch include cereal grains (e.g., rice, wheat, and corn) and root vegetables (e.g., potato and cassava). Other examples of starch sources include acorn, arrowroot, arracacha, banana, barley, legumes (e.g., fava, lentil, mung bean, pea, chickpea), breadfruit, buckwheat, canna, chestnut, taro (colacasia), dogtooth violet, arrowroot, malanga, millet, oat, okara, yam, sago, sorghum, sweet potato, quinoa, rye, tapioca, taro, tobacco, water chestnut, and yam. Suitable starches include, but are not limited to, corn starch, rice starch, tapioca starch, and modified food starches. Certain starches are modified starches. Modified starches have one or more structural modifications, often designed to alter their high-heat properties. Some starches are produced by genetic engineering and are considered "modified" starches. Other starches are obtained and then modified.For example, modified starches can be starches that have been subjected to chemical reactions such as esterification, etherification, oxidation, depolymerization (thinning) by acid catalysis or oxidation in the presence of a base, bleaching, transglycosylation and depolymerization (e.g., dextrinization in the presence of a catalyst), crosslinking, enzyme treatment, acetylation, hydroxypropylation, and / or partial hydrolysis. Other starches are modified by heat treatments such as pregelatinization, dextrinization, and / or cold water swelling processes. Specific modified starches include monostarch phosphate, distarch glycerol, distarch phosphate esterified with sodium trimetaphosphate, phosphate distarch phosphate, acetylated distarch phosphate, starch acetate esterified with acetic anhydride, starch acetate esterified with vinyl acetate, acetylated distarch adipate, acetylated distarch glycerol, hydroxypropyl starch, hydroxypropyl distarch glycerol, and starch sodium octenyl succinate.

[0091] In some embodiments, the filler comprises corn starch, rice starch or rice flour, modified food starch, or a combination thereof. In other embodiments, the substrate is substantially free or completely free of rice starch and rice flour. "Substantially free" of rice starch and rice flour means that no rice starch or wheat flour has been intentionally added, e.g., beyond trace amounts that may be naturally present in another starch material. For example, certain embodiments may be characterized as having less than 0.1% by dry weight, or less than 0.01% by dry weight, or less than 0.001% by dry weight, or 0% by dry weight of rice starch and rice flour, based on the total dry weight of the substrate.

[0092] In some embodiments, the filler comprises a sugar. Suitable sugars include, but are not limited to, glucose, dextrose, fructose, maltose, and lactose.

[0093] In some embodiments, the filler comprises a sugar alcohol. Suitable sugar alcohols include, but are not limited to, sorbitol, mannitol, isomalt, maltitol, erythritol, and xylitol.

[0094] Inorganic / inert substances In some embodiments, the filler includes inorganic or inert materials, such as, but not limited to, chitosan, carbon (graphite, diamond, fullerene, graphene), quartz, granite, diatomaceous earth, calcium carbonate, calcium phosphate, clay, crustacean and other marine shells, or combinations thereof. In some embodiments, the substrate material can include various types of inorganic fibers (e.g., fiberglass, metal wire / screen, etc.) and / or (organic) synthetic polymers. In some embodiments, these "fibrous" materials can be unstructured (e.g., randomly distributed like cellulose fibers in tobacco cast sheets) or unstructured (e.g., wire mesh) materials.

[0095] Binder The substrates disclosed herein include a binder. The binder (or combination of binders) may be utilized in an amount sufficient to provide the substrate with the desired physical characteristics and physical integrity. The amount of binder utilized may vary. In some embodiments, the binder is present in an amount of about 1%, 5%, 10%, 15%, 20%, 25%, 30%, or 35% to about 40%, 45%, 50%, 55%, or 60% by weight, based on the dry weight of the substrate. Certain embodiments are characterized by a binder content of at least about 1% by weight, e.g., about 1% to about 30% by weight, or about 1% to about 20% by weight, or about 5% to about 15% by weight, based on the total wet weight of the substrate. In some embodiments, the binder is present in an amount of about 5% to about 20% by weight, or about 8% to about 18% by weight, or about 10% to about 20% by weight, based on the total dry weight of the substrate.

[0096] Typical binders may be organic or inorganic or a combination thereof. Exemplary binders include povidone, alginates, seaweed hydrocolloids, pectin, starch, gums, carrageenan, pullulan, zein, cellulose derivatives, and the like, and combinations thereof. In some implementations, a combination or blend of two or more binder materials may be utilized.

[0097] In some embodiments, the binder comprises alginate, pectin, agar, agarose, gelatin, carrageenan, gum, cellulose derivatives, pullulan, starch or derivatives thereof, silica or silicone compounds, clay, polymers, or combinations thereof.

[0098] In some embodiments, the binder comprises an alginate, such as ammonium alginate, propylene glycol alginate, potassium alginate, or sodium alginate. Alginates, particularly high viscosity alginates, can be utilized as crosslinkers in conjunction with controlled levels of free calcium ions. In some embodiments, the substrate comprises about 1 to about 15% alginate, for example, about 5 to about 10% by weight, on a dry weight basis, based on the total dry weight of the substrate.

[0099] In some embodiments, the binder comprises pectin. In some embodiments, the binder comprises alginate and / or pectin, which can be combined with a stiffening agent (e.g., a calcium source) during formation of the substrate. In some embodiments, the substrate can comprise calcium-crosslinked alginate, calcium- or acid-crosslinked pectin, or both.

[0100] In some embodiments, the binder comprises a gum, such as a natural gum. As used herein, natural gum refers to a naturally occurring polysaccharide material that has binding properties and is also useful as a thickening or gelling agent. Representative natural gums derived from plants, which are typically water-soluble to some extent, include xanthan gum, guar gum, gum arabic, ghatti gum, tragacanth gum, gum karya, locust bean gum, gellan gum, and combinations thereof. In some embodiments, the binder comprises xanthan gum, guar gum, gum arabic, locust bean gum, tragacanth gum, or combinations thereof.

[0101] In some embodiments, the binder comprises silica, fumed silica, sodium silicate, polydimethylsiloxane, kaolin, polyvinyl alcohol, or a combination thereof.

[0102] In some embodiments, the binder comprises a cellulose ether (including a carboxyalkyl ether), which refers to a cellulose polymer in which the hydrogen of one or more hydroxyl groups in the cellulose structure is replaced with an alkyl, hydroxyalkyl, or aryl group. Non-limiting examples of such cellulose derivatives include methyl cellulose, hydroxypropyl cellulose ("HPC"), hydroxypropyl methyl cellulose ("HPMC"), hydroxyethyl cellulose, and carboxymethyl cellulose ("CMC"). Suitable cellulose ethers include hydroxypropyl cellulose, such as Klucel H from Aqualon Co.; hydroxypropyl methyl cellulose, such as Methocel K4MS from DuPont; hydroxyethyl cellulose, such as Natrosol 250 MRCS from Aqualon Co.; methyl cellulose, such as Methocel A4M, K4M, and E15 from DuPont; and sodium carboxymethyl cellulose, such as CMC 7HF, CMC 7LF, and CMC 7H4F from Aqualon Co. In some embodiments, the binder is one or more cellulose ethers (e.g., a single cellulose ether or several cellulose ethers, e.g., a combination of two or three). In some embodiments, the binder is a cellulose ether selected from the group consisting of methylcellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose, hydroxyethyl cellulose, carboxymethyl cellulose, and combinations thereof. In some embodiments, the binder is carboxymethyl cellulose. In some embodiments, the binder is hydroxypropyl methyl cellulose.

[0103] In some embodiments, the substrate comprises carboxymethyl cellulose in an amount of about 5 to about 11 wt % or about 7 to about 9 wt %, based on the dry weight of the substrate.

[0104] Aerosol-forming materials The substrates disclosed herein include an aerosol-forming material, which may also be referred to as a humectant. Suitable aerosol-forming materials include, but are not limited to, water, polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, terpenes, sugar alcohols, tobacco extracts, and combinations thereof. In some embodiments, the aerosol-forming material can include water, polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, triacetin, waxes, terpenes, cannabinoids, sugar alcohols, tobacco extracts, or any combination thereof. Each of the polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, terpenes, and sugar alcohols is further described herein below.

[0105] The amount of aerosol-forming material incorporated (e.g., loaded or impregnated) into the substrate can vary and is generally such that the aerosol-generating element, including the substrate, provides acceptable sensory properties and desirable performance characteristics. For example, it is highly preferred that a sufficient amount of aerosol-forming material be utilized to provide for the production of a visible mainstream aerosol that is similar in appearance to tobacco smoke in many respects. The amount of forming material (e.g., impregnated substrate) within the aerosol-generating element can depend on factors such as the number of puffs desired per aerosol-generating element.

[0106] In some embodiments, the substrate, upon loading, comprises at least about 0.1 wt.%, at least about 0.5 wt.%, at least about 1 wt.%, at least about 5 wt.%, at least about 10 wt.%, at least about 15 wt.%, at least about 20 wt.%, at least about 25 wt.%, at least about 30 wt.%, at least about 35 wt.%, at least about 40 wt.%, at least about 45 wt.%, at least about 50 wt.%, at least about 55 wt.%, at least about 60 wt.%, at least about 65 wt.%, at least about 70 wt.%, at least about 75 wt.%, or at least about 80 wt.% aerosol-forming material, based on the total dry weight of the impregnated substrate. Exemplary ranges of total aerosol-forming material include from about 5 to about 80%, from about 10 to about 70%, or from about 20 to about 60%, e.g., from about 15% to about 55%, from about 15% to about 30%, or from about 15% to about 25%, based on the total dry weight of the impregnated substrate. In some embodiments, the substrate comprises the aerosol-forming material in an amount of about 10 to about 70 wt %, about 40 to about 60 wt %, about 30 to about 60 wt %, or about 25 to about 45 wt %, based on the dry weight of the substrate.

[0107] In some embodiments, the aerosol-forming material comprises one or more polyhydric alcohols, examples of which include glycerol (i.e., glycerin), propylene glycol, other glycols such as 1,3-propanediol, diethylene glycol and triethylene glycol, and polyethylene glycol (e.g., PEG molecules having a weight-average molecular weight ranging from about 200 to about 2,000 Da).

[0108] In some embodiments, the polyhydric alcohol is selected from the group consisting of glycerol, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, and combinations thereof. In some embodiments, the polyhydric alcohol is glycerol. In some embodiments, the aerosol-forming material is glycerol.

[0109] In some embodiments, the polyhydric alcohol is a mixture of glycerol and propylene glycol. Glycerol and propylene glycol may be present in various ratios, with more of either component being present depending on the intended use. In some embodiments, glycerol and propylene glycol are present in a weight ratio of about 3:1 to about 1:3. In some embodiments, glycerol and propylene glycol are present in a weight ratio of about 3:1, about 2:1, about 1:1, about 1:2, or about 1:3. In some embodiments, glycerol and propylene glycol are present in a weight ratio of about 1:1.

[0110] In some embodiments, the aerosol-forming material comprises one or more polysorbates. Examples of polysorbates include polysorbate 60 (polyoxyethylene (20) sorbitan monostearate, Tween 60) and polysorbate 80 (polyoxyethylene (20) sorbitan monooleate, Tween 80). The type of polysorbate or combination of polysorbates used depends on the intended desired effect, as different polysorbates offer different properties depending on the size of the molecule. For example, polysorbate molecules increase in size from polysorbate 20 to polysorbate 80. Using smaller sized polysorbate molecules produces lower vapor yields but allows for deeper lung penetration. This may be desirable when the user is in a public location where they do not want to produce a large plume of "smoke" (i.e., vapor). Conversely, if a denser vapor is desired, larger polysorbate molecules can be utilized because they are more capable of delivering the aromatic constituents of tobacco. An added benefit of using the polysorbate family of compounds is that polysorbates reduce the heat of vaporization of mixtures in which they are present.

[0111] In some embodiments, the aerosol-forming material comprises one or more sorbitan esters, examples of which include sorbitan monolaurate, sorbitan monostearate (Span 60), sorbitan monooleate (Span 20), and sorbitan tristearate (Span 65).

[0112] In some embodiments, the aerosol-forming material comprises one or more fatty acids. The fatty acids can include short-chain, long-chain, saturated, unsaturated, straight-chain, or branched-chain carboxylic acids. Fatty acids can be C4 to C6. 28 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.

[0113] In some embodiments, the aerosol-forming material comprises one or more fatty acid esters. Examples of fatty acid esters include alkyl esters, monoglycerides, diglycerides, and triglycerides. Examples of monoglycerides include monolaurin and glycerol monostearate. Examples of triglycerides include triolein, tripalmitin, tristearate, glycerol tributyrate, and glycerol trihexanoate.

[0114] In some embodiments, the aerosol-forming material comprises one or more non-fatty acid esters, examples of which include, but are not limited to, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenyl acetate, and propylene carbonate.

[0115] In some embodiments, the aerosol-forming material comprises one or more waxes, such as carnauba, beeswax, and candelilla, which are known to stabilize aerosol particles, improve palatability, or reduce throat irritation.

[0116] In some embodiments, the aerosol-forming material comprises one or more terpenes. As used herein, the term "terpene" refers to a hydrocarbon compound biosynthetically produced by plants from isopentenyl pyrophosphate. Non-limiting examples of terpenes include limonene, pinene, farnesene, myrcene, geraniol, fennel, and cembrene.

[0117] In some embodiments, the aerosol-forming material comprises one or more sugar alcohols. Examples of sugar alcohols include sorbitol, erythritol, mannitol, maltitol, isomalt, and xylitol. Sugar alcohols can also function as flavor enhancers for certain flavor compounds, such as menthol and other volatiles, and generally improve the mouthfeel, texture, throat effect, and other sensory characteristics of the generated aerosol.

[0118] In some embodiments, the aerosol-forming material comprises glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, propylene carbonate, or any combination thereof, hi some embodiments, the aerosol-forming material comprises, consists essentially of, or consists of glycerol.

[0119] capsule The substrates described herein may further include encapsulated additives, which may provide, for example, the ability for the consumable to deliver more of the user's flavor or additive of choice, which may be beneficial in manufacturing, since the capsule does not need to be included in a filter or other part of the aerosol delivery device when heated. In some embodiments, the additive is present only in the encapsulation. In some embodiments, the additive is present both in the encapsulation and elsewhere in the substrate. The capsule is impregnated or otherwise incorporated into the substrate. For example, impregnation may be performed during preparation of the substrate material.

[0120] In one embodiment, the encapsulation comprises an outer wall or barrier structure and an interior region containing an additive. For example, certain embodiments of the present invention include multiple capsules, each of which comprises an interior or core region encapsulated by an outer shell region. In another embodiment, the capsule further comprises a stabilizer fixedly affixed to the outer wall or barrier structure. The interior region contains an additive payload adapted to enhance one or more sensory properties of the substrate, such as taste, moistness, cooling / heating, and / or fragrance, or to add additional functional qualities to the substrate, such as antioxidant or immune system-enhancing functionality. The outer shell or coating of the capsule acts as a barrier between the substrate payload and the filler. Depending on the desired application, this barrier may be permanent, meaning intended to remain in place as a barrier for the life of the product, or temporary, meaning the barrier is designed to cease functioning as a barrier and thereby release the payload under certain conditions of product use. The stabilizer affixed to the outer shell or coating serves as a means to secure the capsule position within the substrate. As the material surrounding the capsules moves and shifts, the stabilizer can limit the movement of the capsules, for example, preventing removal of the capsules from the substrate portion of the aerosol generating element.

[0121] In many embodiments, the additives in the core region are released when the outer shell is subjected to some type of physical disruption, breakage, or other loss of physical integrity (e.g., via disintegration, softening, crushing, application of pressure, etc.), thereby altering the sensory or functional properties of the substrate during use of the product. Thus, for example, a capsule can be incorporated into the substrate, and contact of the capsule with moisture during use can cause the capsule to soften, lose its physical integrity, and release the additive. Alternatively, when the capsule comes into contact with an enzyme, the capsule can soften, lose its physical integrity, and release the additive. In another example, when exposed to elevated temperatures (e.g., 60-200°C), the capsule can soften, lose its physical integrity, and release the additive. Such activation and release of the additive can alter or enhance the flavor or other sensory properties of the substrate, extending the time during which the user can enjoy the substrate or obtain other functional benefits.

[0122] The internal payload of the capsule can also include any type of additive useful for use in aerosol-forming substrates for aerosol delivery devices, including aerosol-forming materials, active ingredients, or flavoring substances.

[0123] active ingredient 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 naturally occurring substances that can have an effect in humans. Exemplary active ingredients include any ingredient known to affect one or more biological functions in the body, such as ingredients that provide pharmacological activity or other direct effect 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., producing a stimulating effect on the central nervous system, having an energizing effect, an antipyretic or analgesic effect, or otherwise having a beneficial effect on the body). In some embodiments, the active ingredient can be of the type commonly referred to as a dietary supplement, nutraceutical, "botanical compound," or "functional food." These types of additives are sometimes defined in the art to include substances that provide one or more beneficial biological effects (e.g., health-promoting, disease-preventing, or other pharmacological effects) but are commonly available from naturally occurring sources (e.g., botanical materials) that are not classified or regulated as drugs.

[0124] Non-limiting examples of active ingredients include those in the categories of synthetic organic compounds, proteins and peptides, polysaccharides and other sugars, lipids, inorganic compounds, and nucleic acid sequences, which have therapeutic, preventative, or diagnostic activity. Non-limiting examples of active ingredients include those in the categories of botanical ingredients, stimulants (e.g., caffeine and guarana), amino acids (e.g., taurine, theanine, phenylalanine, tyrosine, and tryptophan), and / or pharmaceutical ingredients, nutraceutical ingredients, and medicinal ingredients (e.g., vitamins such as B6, B12, and C, and / or cannabinoids such as tetrahydrocannabinol (THC) and cannabidiol (CBD)), antioxidants, and nicotine ingredients. The specific choice of active ingredient will depend on the desired flavor, texture, and desired characteristics of the particular product.

[0125] The specific percentage of active ingredients present will vary depending on the desired characteristics of the particular product. Typically, the active ingredient or combination thereof will be present at 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 will be present at 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, about 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 from about 0.001 wt.%, about 0.01 wt.%, about 0.1 wt.%, or about 1 wt.%, up to about 20 wt.%, for example, about 0.001 wt.%, about 0.002 wt.%, about 0.003 wt.%, about 0.004 wt.%, about 0.005 wt.%, about 0.006 wt.%, about 0.007 wt.%, about 0.008 wt.%, about 0.009 wt.%, about 0.01 wt.%, about 0.02 wt.%, about 0.03 wt.%, about 0.04 wt.%, about 0.05 wt.%, about 0.06 wt.%, about 0.07 wt.%, based on the total weight of the composition. The active ingredient may be present in a concentration of about 0.08%, about 0.09%, about 0.1%, about 0.2%, about 0.3%, about 0.4%, about 0.5%, about 0.6%, about 0.7%, about 0.8%, or about 0.9% by weight, up to about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about 10%, about 11%, about 12%, about 13%, about 14%, about 15%, about 16%, about 17%, about 18%, about 19%, or about 20% by weight. Further suitable ranges for particular active ingredients are provided herein below.

[0126] botanical 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 (e.g., leaves, bark, fiber, stems, roots, seeds, flowers, fruit, pollen, husks, etc.) and plant material derived from natural plant material, such as an extract or isolate from the plant material, or processed plant material (e.g., plant material that has been subjected to heat treatment, fermentation, or other treatment processes that can alter the chemical properties of the material).

[0127] For purposes of this disclosure, "botanical materials" includes, but is not limited to, "herbal materials," which refer to seed-bearing plants that do not produce persistent xylem tissue and are often valued for their medicinal or sensory properties (e.g., tea or tisane). Referring to botanical materials as "non-tobacco" is intended to exclude tobacco materials (i.e., not including any Nicotiana species). Botanical materials, as used in this disclosure, can include, without limitation, any of the compounds and sources described herein, including mixtures thereof. Certain botanical materials of this type are sometimes referred to as dietary supplements, nutraceuticals, "phytocompounds," or "functional foods."

[0128] Non-limiting examples of botanical ingredients, many of which have antioxidant properties, include, without limitation, acai berry, alfalfa, allspice, aniseed, annatto seed, apricot oil, ashwagandha, bacopa monniera, baobab, basil, bay leaf, bee balm, beetroot, bergamot, black pepper, black tea, blueberry, borage seed oil, ambrosia, cacao, calamus root, cardamom, black currant, catnip, catuaba, cayenne pepper, Centella asiatica, and others. asiatica), chaga, bupleurum, chamomile, cherry blossom, chervil, chives, chlorophyll, dark chocolate, coriander, cinnamon, citrus, cloves, cocoa, coffee, comfrey, black cohosh, cordyceps, coriander, cranberry, cumin, curcumin, damiana, dandelion, Dorstenia arifolia, Dorstenia odorata, echinacea, elderberry, eucalyptus, fennel, feverfew, flax, Galphimia glauca, garlic, geranium, ginger, ginkgo biloba, ginseng (e.g., Panax ginseng), goji berry, goldenseal, grape seed, green tea, grapefruit, Griffonia simplicifolia simplicifolia, guarana, gotu kola, hawthorn, hazel, cannabis, hibiscus flower, honeybush, hops, jasmine, gynostemma, juniper, Kaempferia parviflora (black ginger), kava, laurel, lavender, lemon, lemon balm, lemongrass, licorice, Yamabushitake mushroom, lutein, maca, mace, marjoram, matcha, mulberry, Nardostachys chinensischinensis, marjoram, milk thistle, mint, myrtle, nutmeg, olive, oolong tea, orange, oregano, papaya, paprika, morning glory, peppermint, pimento, potato skin, primrose, quercetin, red clover, resveratrol, Rhizoma gastrodiae, rhodiola, rooibos, rooibos (red or green), rose essential oil, rosehip, rosemary, saffron, sage, clary sage, sandalwood, savory, saw palmetto, Sceletium tortuosum, schisandra, silybum marianeum marianum, skullcap, spearmint, spikenard, spirulina, slippery elm bark, high-tannin sorghum bran, high-tannin sorghum grain, St. John's wort, star anise, bearberry, tarragon, terpenes, thyme, tisane, turmeric, Turnera aphrodisiaca, uva-ursi, valerian, vanilla, Viola odorata, white mulberry, wild yam root, wintergreen, Withania somnifera, yacon root, yellow dock, yerba mate, and yerba santa.

[0129] In some embodiments, the active ingredient comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof, wherein the botanicals are selected from eucalyptus, star anise, cocoa and cannabis.

[0130] When present, the botanical active ingredient is typically present at a concentration of from about 0.01% w / w to about 10% by weight, for example, from about 0.01% w / w, about 0.05% w / w, about 0.1% w / w or about 0.5% w / w 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 base composition.

[0131] Nicotine content In some embodiments, the active ingredient comprises a nicotine component. By "nicotine component" is meant any suitable form of nicotine (e.g., free base or salt) that results in systemic absorption of at least a portion of the nicotine present. The source of the nicotine can vary and can be natural or synthetic. Most preferably, the nicotine is naturally derived and obtained as an extract from Nicotiana species (e.g., tobacco). The nicotine can have the enantiomeric form S-(-)-nicotine, R-(+)-nicotine, or a mixture of S(-)-nicotine and R-(+)-nicotine. Most preferably, the nicotine is in the form of S-(-)-nicotine (e.g., a form that is substantially all S(-)-nicotine) or a racemic mixture composed primarily or predominantly of S-(-)-nicotine (e.g., a mixture composed of about 95 parts by weight of S-(-)-nicotine and about 5 parts by weight of R-(+)-nicotine). Most preferably, the nicotine is utilized in a substantially pure form or an essentially pure form. Highly preferred nicotine utilized has a purity of greater than about 95 percent, more preferably greater than about 98 percent, and most preferably greater than about 99 percent, based on the weight of the total substrate.

[0132] Typically, the nicotine component is selected from the group consisting of nicotine free base and nicotine salts. In some embodiments, the nicotine is in its free base form. The nicotine may be tobacco-derived (e.g., tobacco extract) or non-tobacco-derived (e.g., synthetically or otherwise obtained). In various embodiments, the substrate (within the capsule and / or elsewhere) may include a nicotine component. In various embodiments, the substrate (within the capsule and / or elsewhere) may be free of a nicotine component. In some embodiments, the substrate (within the capsule and / or elsewhere) may include a non-tobacco-derived nicotine component.

[0133] 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 total substrate, e.g., in the range of about 0.001% to about 10%. In some embodiments, the nicotine component, calculated as the free base, is present in a concentration of about 0.1% w / w to about 10% by weight, e.g., about 0.1%, 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%, up to about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, or about 10% by weight, based on the total weight of the substrate. In some embodiments, the nicotine component, calculated as the free base, is present in a concentration of about 0.1% w / w to about 3% by weight, e.g., about 0.1% w / w to about 2.5% by weight, about 0.1% w / w to about 2.0% by weight, about 0.1% w / w to about 1.5% by weight, or about 0.1% w / w to about 1% by weight, based on the total weight of the substrate. These ranges may also apply to other active ingredients described herein.

[0134] In some embodiments, the substrates of the present disclosure can be characterized as being completely free or substantially free of nicotine components. "Substantially free of nicotine components" means that no nicotine has been intentionally added beyond trace amounts that may be naturally present, for example, in botanical materials. For example, certain embodiments can be characterized as having less than 0.001% by weight nicotine, or less than 0.0001% by weight, or even 0% by weight nicotine, calculated as the free base.

[0135] cannabinoids In some embodiments, the active ingredient comprises one or more cannabinoids. As used herein, the term "cannabinoid" refers to a class of diverse natural or synthetic chemical compounds that act on intracellular cannabinoid receptors (e.g., CB1 and CB2) to alter neurotransmitter release in the brain. Cannabinoids are cyclic molecules that exhibit specific properties, such as the ability to easily cross the blood-brain barrier. Cannabinoids may be naturally derived from plants such as cannabis (phytocannabinoids), naturally derived from animals (endocannabinoids), or artificially produced (synthetic cannabinoids). Cannabis species express at least 85 different phytocannabinoids, including cannabigerol, cannabichromene, cannabidiol, tetrahydrocannabinol, cannabinol, and cannabinodiol, as well as other cannabinoids such as cannabigerol (CBG), cannabichromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol (CBN), and cannabinodiol (CBDL), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabinerolic acid, cannabidiolic acid (CBDA), cannabinol propyl variants (CBNV), cannabidiol (CBO), tetrahydrocannabinolic acid (tetrahydrocannabmolic It can be divided into subclasses including tetrahydrocannabivaric acid (THCA) and tetrahydrocannabivaric acid (THCV A).

[0136] In some embodiments, the cannabinoid is selected from the group consisting of cannabigerol (CBG), cannabichromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol (CBN) and cannabinodiol (CBDL), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabinerolic acid, cannabidiolic acid (CBDA), cannabinol propyl variants (CBNV), cannabiditriol (CBO), tetrahydrocannabmolic acid (THCA), tetrahydrocannabivarinic acid (THCV A), and mixtures thereof. In some embodiments, the cannabinoid comprises at least tetrahydrocannabinol (THC). In some embodiments, the cannabinoid is tetrahydrocannabinol (THC). In some embodiments, the cannabinoid comprises at least cannabidiol (CBD). In some embodiments, the cannabinoid is cannabidiol (CBD). In some embodiments, the CBD is synthetic CBD. Notably, CBD has a log P value of about 6.5, which makes it insoluble in aqueous environments (e.g., saliva).

[0137] In some embodiments, the cannabinoid (e.g., CBD) is added to the capsule and / or elsewhere in the substrate in the form of an isolate, which is an extract from a plant, such as cannabis, in which the active substance of interest (in this case the cannabinoid, e.g., CBD) is present at a high degree of purity, for example, greater than 95%, greater than 96%, greater than 97%, greater than 98%, or around 99% purity.

[0138] In some embodiments, the cannabinoid is a highly pure CBD isolate and the amount of any other cannabinoid in the capsule is about 1% or less by weight of the total substrate, such as about 0.5% or less by weight of the total substrate, for example about 0.1% or less by weight of the total substrate, for example about 0.01% or less by weight of the total substrate.

[0139] The selection of cannabinoids and their specific percentages that may be present in the disclosed capsules and / or substrates will depend on the desired characteristics of the substrate.

[0140] In some embodiments, the cannabinoid (e.g., CBD) is present in the capsules and / or elsewhere in the substrate at a concentration of at least about 0.001% by weight of the total substrate, for example, in the range of about 0.001% to about 2% by weight of the total substrate. In some embodiments, the cannabinoid (e.g., CBD) is present in the substrate at a concentration of about 0.1% to about 1.5% by weight based on the total weight of the substrate. In some embodiments, the cannabinoid (e.g., CBD) is present in the substrate at a concentration of about 0.4% to about 1.5% by weight based on the total weight of the substrate.

[0141] Instead of or in addition to cannabinoids, the active ingredient can include cannabimimetics, which are a class of compounds derived from plants other than cannabis that have similar biological effects on the endocannabinoid system as cannabinoids. Examples include yangonin, α-amyrin or β-amyrin (also classified as terpenes), cyanidin, curcumin (turmeric), catechin, quercetin, salvinorin A, N-acylethanolamines, and N-alkylamide lipids. Such compounds can be used in the same amounts and ratios as those described herein for cannabinoids.

[0142] In some embodiments, the active ingredients include nicotine and cannabidiol (CBD). In some embodiments, the active ingredients include nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol). In some embodiments, the active ingredients include nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids or constituents, derivatives, or combinations thereof.

[0143] terpenes Active ingredients suitable for use in the present disclosure can also be classified as terpenes, many of which are associated with biological effects, such as sedative effects. Terpenes have the general formula (C5H8): n Terpenes are believed to have the formula: and include monoterpenes, sesquiterpenes, and diterpenes. Terpenes can be acyclic, monocyclic, or bicyclic in structure. Some terpenes, when used in combination with cannabinoids or cannabimimetics, produce an entourage effect. Examples include β-caryophyllene, linalool, limonene, β-citronellol, linalyl acetate, pinene (α or β), geraniol, carvone, eucalyptol, menthone, iso-menthone, piperitone, myrcene, β-bourbonene, and germacrene, which can be used individually or in combination.

[0144] In some embodiments, the terpene is derivable from a plant that produces phytocannabinoids, such as a plant of the Cannabis sativa species, e.g., cannabis. Suitable terpenes in this regard include so-called "C10" terpenes (which are terpenes containing 10 carbon atoms) and so-called "C15" terpenes (which are terpenes containing 15 carbon atoms). In some embodiments, the active ingredient comprises more than one terpene. For example, the active ingredient may comprise one, two, three, four, five, six, seven, eight, nine, ten, or more terpenes as defined herein. In some embodiments, the terpene is selected from pinene (α and β), geraniol, linalool, limonene, carvone, eucalyptol, menthone, iso-menthone, piperitone, myrcene, β-bourbonene, germacrene, and mixtures thereof.

[0145] The terpene and / or cannabinoid may be present in the capsule and / or elsewhere in the substrate as an active ingredient, as an aerosol-forming material, or as a flavoring ingredient. The amount of terpene and / or cannabinoid present may thus vary based on its intended purpose.

[0146] Flavoring substances In some embodiments, the capsule and / or other locations in the substrate contain a flavoring substance. The flavoring substance may be a component of the aerosol-forming material or may be impregnated separately. Impregnation can occur during preparation of the substrate material, after formation of the substrate, or both. As used herein, reference to a "flavoring substance" refers to a compound or ingredient that can be aerosolized and delivered to a user to impart a sensory experience in terms of taste and / or aroma. Flavoring substances 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 substances include, but are not limited to, aloe vera, aniseed, apple, Asian spices, bacopa monniera, basil, bay leaf, shiso, bergamot, berries, betel quid, blueberry, bourbon, camphene, hemp, caraway, cardamom, caramel, cascarilla, cassia, black currant, celery, chamomile, cherry, cherry blossom, chives, coriander, cinnamon, citrus fruits, clementine, black Beans, cocoa, coffee, cognac, coriander, cranberry, cucumber, cumin, turmeric, damien, dragon fruit, drambuie, durian, elderberry, eucalyptus, eugenol, fennel, fenugreek, flax, geranium, gin, ginger, ginkgo biloba, grapes, guayusa, hazel, cannabis, hibiscus, honeybush, honey essence, hydrangea, Indian spices, jasmine, juniper, kale Lavender, laurel, lemon, lemongrass, lemon balm, lemon oil, lemon peel, licorice, lime, limonene, mace, magnolia leaf, mango, maple, marjoram, matcha, yerba mate, menthol, mint, myrtle, mulberry, nasturtium, nutmeg, olive, orange blossom, orange oil, orange peel, oregano, papaya, paprika, peach, peppermint, pimento, pineapple , rhubarb, rooibos, rosemary, rosehips, rose oil, rum, saffron, sage, sandalwood, scotch, shisha, spearmint, strawberry, tarragon, tea (e.g., green or black tea), tequila, terpenes, thyme, tobacco, tropical fruits, turmeric, valerian, vanilla, verbena, wasabi, whiskey, wintergreen, withania somnifera, yerba mate, yerba santa, ylang ylang, and combinations thereof.

[0147] Flavoring substances can further include flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulators, and trigeminal sensates, where "trigeminal sensates," as used herein, refer to flavoring agents that have an effect on the trigeminal nerve and produce sensations including warmth, coolness, tingling, etc. Non-limiting examples of flavoring agents that are trigeminal sensates include capsaicin, citric acid, menthol, Sichuan buttons, erythritol, and cubebol.

[0148] Further non-limiting examples include flavorings and flavor packages of the type and nature customarily used in the flavoring of cigarettes, cigars, and pipe tobacco. See also Leffingwell et al., Tobacco Flavoring for Smoking Products, R.J. Reynolds Tobacco Company (1972), incorporated herein by reference. Flavoring agents can include components such as terpenes, terpenoids, aldehydes, ketones, esters, and the like. Syrups, such as high fructose corn syrup, can also be utilized. Some examples of potentially suitable plant-derived compositions are disclosed in U.S. Patent No. 9,107,453 to Dube et al. and U.S. Patent Application Publication No. 2012 / 0152265, both of which are incorporated herein by reference in their entireties. The selection of such additional ingredients will vary based on factors such as the sensory characteristics desired for the smoking article, their affinity for the substrate material, their solubility, and other physiochemical properties. The present disclosure is intended to encompass any such additional ingredients readily apparent to those skilled in the art of tobacco and tobacco-related or tobacco-derived products. See, for example, Gutcho, Tobacco Flavoring Substances and Methods, Noyes Data Corp. (1972) and Leffingwell et al., Tobacco Flavoring for Smoking Products (1972), the disclosures of which are incorporated herein by reference in their entireties. Note that reference to flavoring substances should not be limited to any single flavoring substance as described above, but may in fact represent a combination of one or more flavoring substances. Additional flavoring substances, flavoring agents, additives, and other possible enhancing components are described in U.S. Patent Application Serial No. 15 / 707,461 to Phillips et al., which is incorporated herein by reference in its entirety.

[0149] The amount of flavor substance present may vary and, if present, is generally less than about 30%, or less than about 20% by weight of the total base material. For example, the flavor substance 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 total base material.

[0150] water The moisture (e.g., water) content of the substrate may vary. For example, in some embodiments, the substrate contains about 0% to about 30% water. In some embodiments, the substrate is dried to remove at least a portion of the water present during preparation. In some embodiments, after drying, the substrate containing capsules contains about 3 to about 21% water, based on the total weight of the substrate. In some embodiments, after drying, the substrate containing capsules contains about 8 to about 10 or about 12 to about 18% water, based on the total weight of the substrate. In some embodiments, after drying, the substrate containing capsules contains about 15 to about 21% water, based on the total weight of the substrate.

[0151] coloring agent In some embodiments, the substrate comprises a colorant. The addition of a colorant can change the visual appearance of the substrate. The presence of a colorant can enhance the visual appearance of the substrate and / or the aerosol-generating element and / or capsule containing the substrate. By adding a colorant to the substrate, the substrate can be color-matched to other components of the aerosol-generating element or to other components of an article containing the substrate.

[0152] Various colorants can be used depending on the desired color of the substrate. The color of the substrate can be, for example, white, green, red, purple, blue, brown, or black. Other colors are also contemplated herein. Natural or synthetic colorants, such as natural or synthetic dyes, food-grade colorants, and pharmaceutical-grade colorants, may be used. In certain embodiments, the colorant is caramel, which can impart a brown appearance to the substrate. In such embodiments, the color of the substrate can be similar to the color of other components (e.g., tobacco material) in the aerosol-generating element that includes the substrate. In some embodiments, the colorant is added to the substrate to make it visually indistinguishable from the other components. The colorant can be incorporated during formation of the substrate (e.g., when forming a slurry containing the materials that form the substrate or by incorporating the colorant into capsules), or the colorant can be applied to the substrate after formation (e.g., by spraying the substrate).

[0153] Tobacco Materials In some embodiments, the substrate, the aerosol-generating element comprising the substrate, the capsule, or a combination thereof, comprises tobacco material. The tobacco material can vary in species, variety, and form. Typically, tobacco material is obtained from harvested plants of the Nicotiana genus. Exemplary Nicotiana species include N. tabacum, N. rustica, N. alata, N. arentzii, N. excelsior, N. forgetiana, N. glauca, N. glutinosa, N. gossei, and N. kawakamii. akamii, N. knightiana, N. langsdorffi, N. otophora, N. setchelli, N. sylvestris, N. tomentosa, N. tomentosiformis, N. undulata, Nx sanderae sanderae, N. africana, N. amplexicaulis, N. benavidesii, N. bonariensis, N. debneyi, N. longiflora, N. maritina, N. megalosiphon, N. occidentalis, N. paniculata paniculata, N. plumbaginifolia, N. raimondii, N. rosulata, N. simulans, N. stocktonii, N. suaveolens, N. umbratica, N. velutina, N. wigandioides, N. acaulis, N.acaulis, N. acuminata, N. attenuata, N. benthamiana, N. cavicola, N. clevelandii, N. cordifolia, N. corymbosa, N. fragrans, N. goodspeedii, N. linearis, N. miersii, N. nudicaulis, N. obtusifolia, N. occidentalis subsp. hesperis subsp. Hersperis, N. pauciflora, N. petunioides, N. quadrivalvis, N. repanda, N. rotundifolia, N. solanifolia and N. spegazzinii. Various representative other types of plants from the species of Nicotiana are described in Goodspeed, The Genus Nicotiana, (Chonica Botanica) (1954); U.S. Pat. No. 4,660,577 to Sensabaugh, Jr. et al.; U.S. Pat. No. 5,387,416 to White et al.; U.S. Pat. No. 7,025,066 to Lawson et al.; U.S. Pat. No. 7,798,153 to Lawrence, Jr.; and U.S. Pat. No. 8,186,360 to Marshall et al., each of which is incorporated herein by reference. A description of various types of tobacco, growing practices, and harvesting practices is provided in Tobacco Production, Chemistry and Technology, Davis et al. (eds.) (1999), which is incorporated herein by reference.

[0154] Nicotiana species from which suitable tobacco materials can be obtained can be derived using genetic modification or cross-breeding techniques (e.g., tobacco plants can be genetically engineered or cross-bred to increase or decrease the production of components, characteristics, or traits). See, for example, the types of genetic modifications of plants described in US Pat. Nos. 5,539,093 to Fitzmaurice et al.; 5,668,295 to Wahab et al.; 5,705,624 to Fitzmaurice et al.; 5,844,119 to Weigl; 6,730,832 to Dominguez et al.; 7,173,170 to Liu et al.; 7,208,659 to Colliver et al. and 7,230,160 to Benning et al.; US Patent Appl. Pub. No. 2006 / 0236434 to Conkling et al.; and PCT WO2008 / 103935 to Nielsen et al. See also the tobacco types described in US Pat. Nos. 4,660,577 to Sensabaugh, Jr. et al.; 5,387,416 to White et al.; and 6,730,832 to Dominguez et al., each of which is incorporated herein by reference.

[0155] In some embodiments, Nicotiana species can be selected for the content of various compounds present therein. For example, plants can be selected based on the fact that they produce relatively high amounts of one or more desired compounds to be isolated from these plants. In certain embodiments, Nicotiana species (e.g., Nicotiana tabacum) plants are specifically cultivated for their high abundance of these leaf surface compounds. Tobacco plants can be grown outdoors in greenhouses, growth chambers, or fields, or grown hydroponically.

[0156] Various parts or portions of a plant of a Nicotiana species may be included within the substrate (in capsules and / or elsewhere) disclosed herein. For example, substantially all of the plant (e.g., the entire plant) can be harvested and utilized as is. Alternatively, various parts or pieces of the plant can be harvested or separated for further use after harvest. For example, flowers, leaves, stems, stalks, roots, seeds, and various combinations thereof can be isolated for further use or processing. In some embodiments, the tobacco material comprises tobacco leaf (lamina). The substrate (in capsules and / or elsewhere) disclosed herein can include processed tobacco parts or pieces, cured and aged tobacco in essentially natural lamina and / or stem form. In certain embodiments, the tobacco material comprises a solid tobacco material selected from the group consisting of lamina and stem. The tobacco used for the substrate (in capsules and / or elsewhere) is most preferably tobacco lamina or a tobacco lamina and stem mixture, at least a portion of which is smoke-treated. The tobacco portion can have a processed form, such as processed tobacco stems (e.g., cut-rolled stems, cut-rolled expanded stems, or cut-puffed stems) or volume-expanded tobacco (e.g., expanded tobacco, e.g., dry ice expanded tobacco (DIET)). See, for example, the tobacco expansion methods described in U.S. Pat. Nos. 4,340,073 to de la Burde et al.; 5,259,403 to Guy et al.; and 5,908,032 to Poindexter et al.; and 7,556,047 to Poindexter et al., all of which are incorporated by reference. In addition, the substrate (in the capsule and / or elsewhere) can incorporate fermented tobacco. See also the types of tobacco processing techniques described in PCT Publication No. WO 2005 / 063060 to Atchley et al., which is incorporated by reference herein.

[0157] Tobacco materials are typically used in a form that can be described as particulate, such as shredded, ground, granulated, pulp, or powder form. In some embodiments, tobacco materials are utilized in the form of pieces or pieces having an average particle size between 1.4 millimeters and 250 microns. In some cases, tobacco particles can be sized to pass through a screening mesh to obtain the required particle size range. If desired, air classification equipment can be used to ensure that small sized tobacco particles of the desired size or size range are collected. Granular tobacco pieces of different sizes can be mixed together if desired.

[0158] The manner in which tobacco material is provided in finely divided or powder-type form may vary. Preferably, plant parts or pieces are milled, comminuted, crushed, or pulverized into a particulate form using equipment and techniques for crushing, milling, or the like. The plant, or its parts, may be subjected to external force or pressure (e.g., by being compressed or rolled). When subjected to such processing conditions, the plant or its parts may have a moisture content that approximates its natural moisture content (e.g., its moisture content immediately after harvesting), a moisture content achieved by adding moisture to the plant or its parts, or a moisture content resulting from drying the plant or its parts. For example, powdered, crushed, crushed, pulped, or milled plant pieces or parts may have a moisture content of less than about 25 weight percent, often less than about 20 weight percent, and frequently less than about 15 weight percent. Most preferably, the plant material is in a relatively dry form during crushing or milling using equipment such as a hammer mill, cutter head, air-conditioned mill, or the like. For example, tobacco sections or pieces can be ground or milled when their moisture content is less than about 15 weight percent or less than about 5 weight percent.

[0159] To prepare the substrate, harvested plants of Nicotiana species are typically subjected to a curing process. The tobacco material incorporated into the substrates disclosed herein (in capsules and / or elsewhere) is generally appropriately cured and / or aged material. A description of various types of curing processes for various types of tobacco is provided in Tobacco Production, Chemistry and Technology, edited by Davis et al. (1999). Examples of techniques and conditions for curing flue-cured tobacco are provided in Nestor et al., Beitrage Tabakforsch. Int., Vol. 20, pp. 467-475 (2003), and Peele, U.S. Pat. No. 6,895,974, both of which are incorporated herein by reference. Representative techniques and conditions for air-curing tobacco are described in Groves et al., U.S. Pat. No. 7,650,892; Roton et al., Beitrage Tabakforsch. Int., Vol. 21, pp. 305-320 (2005); and Staaf et al., Beitrage Tabakforsch. Int., Vol. 21, pp. 321-330 (2005), which are incorporated herein by reference. Certain types of tobacco can be subjected to alternative types of curing processes, such as flame-curing or sun-curing.

[0160] In certain embodiments, tobacco materials that may be utilized include flue-cured or Virginia (e.g., K326), Burley, sun-cured (e.g., Indian Kurnool and Oriental tobaccos, including Katerini, Prelip, Komotini, Xanthi, and Yambol tobaccos), Maryland, dark, dark-fired, dark air-cured (e.g., Madol, Pasanda, Cubano, Jatin, and Bezuki tobaccos), light air-cured (e.g., North Wisconsin and Galpao tobaccos), Indian air-cured, Red Russian, and rustica tobaccos, as well as various other rare or specialty tobaccos and various blends of any of the foregoing tobaccos.

[0161] Tobacco materials can also be in so-called "blended" form. For example, tobacco materials can include a mixture of flue-cured, burley (e.g., Malawi burley), and Oriental tobacco parts or pieces (e.g., tobacco composed of or derived from tobacco lamina, or a mixture of tobacco lamina and tobacco stem). For example, a typical blend can incorporate, on a dry weight basis, about 30 parts to about 70 parts burley tobacco (e.g., lamina or lamina and stem) and about 30 parts to about 70 parts flue-cured tobacco (e.g., stem, lamina, or lamina and stem). Other exemplary tobacco blends incorporate, on a dry weight basis, about 75 parts flue-cured tobacco, about 15 parts burley tobacco, and about 10 parts Oriental tobacco; or about 65 parts flue-cured tobacco, about 25 parts burley tobacco, and about 10 parts Oriental tobacco; or about 65 parts flue-cured tobacco, about 10 parts burley tobacco, and about 25 parts Oriental tobacco. Another exemplary tobacco blend incorporates, on a dry weight basis, from about 20 parts to about 30 parts Oriental tobacco and from about 70 parts to about 80 parts flue-cured tobacco.

[0162] Tobacco materials used in the present disclosure can be subjected to, for example, fermentation, bleaching, etc. If desired, tobacco materials can also be subjected to, for example, irradiation, pasteurization, or controlled heat treatment. Such treatment processes are described in detail, for example, in U.S. Pat. No. 8,061,362 to Mua et al., which is incorporated herein by reference. In certain embodiments, tobacco materials can be treated with water and additives capable of inhibiting the reaction of asparagine to form acrylamide upon heating of the tobacco material (e.g., additives selected from the group consisting of lysine, glycine, histidine, alanine, methionine, cysteine, glutamic acid, aspartic acid, proline, phenylalanine, valine, arginine, compositions incorporating divalent and trivalent cations, asparaginase, certain non-reducing sugars, certain reducing agents, phenolic compounds, certain compounds having at least one free thiol group or functional group, oxidizing agents, oxidation catalysts, natural plant extracts (e.g., rosemary extract), and combinations thereof). See, for example, the types of treatment processes described in Chen et al., U.S. Pat. Pub. Nos. 8,434,496, 8,944,072, and 8,991,403, all of which are incorporated herein by reference. In certain embodiments, this type of treatment is useful when the original tobacco material is subjected to heat in the previously described processes.

[0163] In some embodiments, the type of tobacco material is initially selected (e.g., whitened or bleached) to be somewhat visually lighter in color than other tobacco materials. Tobacco pulp can, in certain embodiments, be whitened according to any means known in the art. For example, bleached tobacco material produced by various whitening methods using various bleaching or oxidizing agents and oxidation catalysts can be used. Exemplary oxidizing agents include peroxides (e.g., hydrogen peroxide), chlorites, chlorates, perchlorates, hypochlorites, ozone, ammonia, potassium permanganate, and combinations thereof. Exemplary oxidation catalysts are titanium dioxide, manganese dioxide, and combinations thereof. Methods for treating tobacco with bleaching agents are described, for example, in U.S. Pat. No. 787,611 to Daniels, Jr.; U.S. Pat. No. 1,086,306 to Oelenheinz; U.S. Pat. No. 1,437,095 to Delling; U.S. Pat. No. 1,757,477 to Rosenhoch; U.S. Pat. No. 2,122,421 to Hawkinson; U.S. Pat. No. 2,148,147 to Baier; U.S. Pat. No. 2,170,107 to Baier; U.S. Pat. No. 2,274,649 to Pratz et al.; U.S. Pat. No. 2,770,239 ...274,649 to Pratz et al.; U.S. Pat. No. 2,770,239 to Rosenhoch; U.S. Pat. No. 2,274,649 to Pratz et al.; U.S. Pat. No. 2,274,649 to Rosenhoch; U.S. Pat. No. 2,274,649 to Rosenhoch; U.S. Pat. No. 2,274,649 to Rosenhoch; U.S. Pat. No. 2,274,649 to Rosenho No. 3,612,065 to Rosen; U.S. Pat. No. 3,851,653 to Rosen; U.S. Pat. No. 3,889,689 to Minami; U.S. Pat. No. 3,943,940 to Rosen; U.S. Pat. No. 3,943,945 to Rainer; U.S. Pat. No. 4,143,666 to Rainer; U.S. Pat. No. 4,194,514 to Campbell; U.S. Pat. Nos. 4,366,823, 4,366,824, and 4,388,933 to Rainer et al.; U.S. Pat. No. 4,641,667 to Schmekel et al.; U.S. Pat. No. 5,713,376 to Berger; Byrd U.S. Patent No. 9,339,058 to Beeson et al.; U.S. Patent Nos. 9,420,825 and 10,772,349 to Byrd Jr.No. 9,950,858 to Bjorkholm et al.; U.S. Patent Application Publication No. 2012 / 0067361 to Crooks; U.S. Patent Application Publication No. 2016 / 0073686 to Crooks; U.S. Patent Application Publication Nos. 2017 / 0020183 and 2017 / 0112183 to Bjorkholm; and WO 1996 / 031255 to Giolvas. FRET; McClanahan et al., WO 20200128971 and WO 2021048769; Beeson et al., WO 2013122948(A1); Bjorkholm, WO 2018 / 083114; and Zawadzki et al., WO 2021048768 and WO 2021048770(A1).

[0164] In some embodiments, the whitened tobacco material can have an ISO brightness of at least about 50%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, or at least about 80%. In some embodiments, the whitened tobacco material can have an ISO brightness in the range of about 50 to about 90%, about 55 to about 75%, or about 60 to about 70%. ISO brightness can be measured according to ISO 3688:1999 or ISO 2470-1:2016.

[0165] In some embodiments, the whitened tobacco material can be characterized by a lighter color (e.g., "whitened") compared to untreated tobacco material. White color is often defined with reference to the International Commission on Illumination (CIE) chromaticity diagram. The whitened tobacco material, in certain embodiments, can be characterized as being closer to pure white on the chromaticity diagram than untreated tobacco material.

[0166] The tobacco material may also have at least a portion of the nicotine present removed. Suitable methods for extracting nicotine from tobacco materials are known in the art. In some embodiments, the tobacco material is substantially free of nicotine. "Substantially free" means that only trace amounts are present in the tobacco material. For example, in certain embodiments, the tobacco material may be characterized as having less than 0.001% nicotine by weight, or less than 0.0001% by weight, or even 0% nicotine by weight, calculated as the free base, based on the total weight of the tobacco material.

[0167] The amount of tobacco material present can vary and is generally less than about 65% by weight of the substrate, based on the total weight of the substrate. For example, the tobacco material may be present in an amount of about 0%, about 0.1%, about 0.5%, about 1%, about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, or about 35%, up to about 40%, about 45%, about 50%, about 55%, about 60%, or about 65% by weight of the substrate, based on the total dry weight of the substrate.

[0168] In some embodiments, the substrates of the present disclosure can be characterized as being completely free or substantially free of any tobacco material (e.g., any embodiment disclosed herein can be completely or substantially free of any tobacco material). By "substantially free," it is meant that no tobacco material has been intentionally added beyond trace amounts that may be naturally present, for example, in botanical or herbal materials. For example, certain embodiments can be characterized as having less than 0.5% by weight tobacco material, less than 0.1% by weight tobacco material, less than 0.01% by weight tobacco material, or less than 0.001% by weight tobacco material, or even 0% by weight tobacco material, based on the total wet weight of the substrate.

[0169] tobacco extract In some embodiments, the substrate (in the capsule and / or elsewhere) further comprises a tobacco extract, e.g., an aqueous tobacco extract, added as a component of the aerosol-forming material or added separately (e.g., during preparation of the substrate or impregnated into the substrate after formation). "Tobacco extract," as used herein, refers to an isolated component of tobacco material extracted from solid tobacco pulp by a solvent (e.g., water) that is contacted with the tobacco material in an extraction process. Various extraction techniques for tobacco material can be used to obtain tobacco extracts and tobacco solids. See, for example, the extraction process described in U.S. Pat. Appl. Pub. No. 2011 / 0247640 to Beeson et al., incorporated herein by reference.Other exemplary techniques for extracting tobacco components include those disclosed in 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; 4,589,428 to Keritsis; 4,605,016 to Soga et al.; and 4,605,016 to Poulose et al., all of which are incorporated herein by reference. 716,911; Niven, Jr. et al. 4,727,889; Bernasek et al. 4,887,618; Clapp et al. 4,941,484; Fagg et al. 4,967,771; Roberts et al. 4,986,286; Fagg et al. 5,005,593; Grubbs et al. 5,018,540; White et al. 5,060,669; Fagg 5,065,775; White et al. 5,0 74,319; White et al. 5,099,862; White et al. 5,121,757; Fagg 5,131,414; Munoz et al. 5,131,415; Fagg 5,148,819; Kramer 5,197,494; Smith et al. 5,230,354; Fagg 5,234,008; Smith 5,243,999; Raymond et al. 5,301,694; Gonza 5,318,050 by Lez-Parra et al.; 5,343,879 by Teague; 5,360,022 by Newton; 5,435,325 by Clapp et al.; 5,445,169 by Brinkley et al.; 6,131,584 by Lauterbach; 6,298,859 by Kierulff et al.; 6,772,767 by Mua et al.; and 7,337,782 by Thompson.

[0170] Acid component In some embodiments, the substrate (in the capsule and / or elsewhere) includes an acid component. The presence of an acid component or an acid salt of nicotine in the substrate can improve the sensory attributes of the aerosol, for example, by reducing the harsh taste of nicotine if present in the substrate. If present, the acid, when formed, protonates nicotine to form a nicotine salt in situ in the substrate or in the aerosol. The presence of a nicotine salt results in an aerosol that some users find more satisfying. Furthermore, the presence of an acid can reduce or substantially prevent evaporation of nicotine during preparation of the substrate (e.g., during drying), thereby reducing nicotine loss during manufacturing.

[0171] The amount of acid present in the substrate (including capsules) can vary, for example, from 0% to about 20% by weight, based on the dry weight of the substrate. In some embodiments, the substrate comprises an acid to nicotine molar ratio. In some embodiments, the nicotine to acid molar ratio is 2.2:1 or less, e.g., 1.5:1 or less, or 1:1 or less. In some embodiments, the nicotine to acid molar ratio is 0.5:1 or greater.

[0172] In some embodiments, the acid comprises an acidic functional group having a pKa value, measured at 25° C., in the range of about 2 to about 6, e.g., 3 to 6 or 4 to 5. In some embodiments, the acid can be a monobasic acid, a dibasic acid, a tribasic acid, or a combination thereof.

[0173] In some embodiments, the acid is an organic acid. In some embodiments, the organic acid is a carboxylic acid. In some embodiments, the carboxylic acid comprises at least one carboxyl functional group. In some embodiments, the carboxylic acid is a mono-, di-, or tricarboxylic acid. In some embodiments, the carboxylic acid further comprises an alpha-hydroxy group. In some embodiments, the carboxylic acid further comprises a keto group.

[0174] In some embodiments, the carboxylic acid is selected from the group consisting of succinic acid, lactic acid, benzoic acid, citric acid, tartaric acid, fumaric acid, levulinic acid, acetic acid, malic acid, formic acid, sorbic acid, benzoic acid, propanoic acid, pyruvic acid, and combinations thereof. In some embodiments, the carboxylic acid is lactic acid. In some embodiments, the carboxylic acid is benzoic acid.

[0175] In other embodiments, the acid is an inorganic acid. In some embodiments, the inorganic acid is a mineral acid, such as sulfuric acid, hydrochloric acid, boric acid, phosphoric acid, or a combination thereof.

[0176] Other ingredients In some embodiments, the substrate (in the capsule and / or elsewhere) can further include a flame-retardant material, conductive fibers or particles for thermal conduction / induction heating, or any combination thereof. One example of a flame-retardant material is ammonium phosphate. In some embodiments, other flame / flame-retardant materials and additives may be included within the substrate, including organo-phosphorus compounds, borax, hydrated alumina, graphite, potassium, silica, tripolyphosphates, dipentaerythritol, pentaerythritol, and polyols. Other flame-retardant materials, such as nitrogenous phosphonates, monoammonium phosphate, ammonium polyphosphate, ammonium bromide, ammonium borate, ethanolammonium borate, ammonium sulfamate, halogenated organic compounds, thiourea, and antimony oxide, can also be used. Each aspect of the flame-retardant, flame-retardant, and / or scorch-retardant materials used in the substrate material and / or other components (whether alone or in combination with each other and / or other materials) provides desirable properties independently and is resistant to undesirable off-gassing or melt-type behavior. Various modes and methods for incorporating tobacco into smoking articles, particularly smoking articles configured to intentionally not burn substantially all of the tobacco within the smoking articles, are described in U.S. Pat. No. 4,947,874 to Brooks et al.; U.S. Pat. No. 7,647,932 to Cantrell et al.; U.S. Pat. No. 8,079,371 to Robinson et al.; U.S. Pat. No. 7,290,549 to Banerjee et al.; and U.S. Patent Application Publication No. 2007 / 0215167 to Crooks et al., the disclosures of which are incorporated herein by reference in their entireties.

[0177] The substrate (in the capsule and / or elsewhere) may also include conductive fibers or particles for thermal conduction or induction heating. In some embodiments, the conductive fibers or particles may be arranged in a substantially linear and parallel pattern. In some embodiments, the conductive fibers or particles may also have a substantially random arrangement. In some embodiments, the conductive fibers or particles may be constructed of one or more of an aluminum material, a stainless steel material, a copper material, a carbon material, and a graphite material. In some embodiments, one or more conductive fibers or particles having different Curie temperatures may be included in the substrate material to facilitate inductive heating at different temperatures.

[0178] In still other implementations, the substrate material can include various types of inorganic fibers (e.g., fiberglass, metal wire / screen, etc.) and / or (organic) synthetic polymers. In various implementations, these "fibrous" materials can be unstructured (e.g., randomly distributed) or structured (e.g., wire mesh) materials.

[0179] Capsule form The strength of the capsule is typically sufficient to allow normal handling and storage without premature or undesirable significant breakage.Exemplary capsules include an outer shell incorporating materials such as wax, gelatin, genipin-crosslinked gelatin, polyhydroxyalkanoate (PHA), polycaprolactone (PCL), pullulan, glucan, chitosan, and ethylcellulose, cyclodextrin, or alginate, and an inner payload incorporating an aqueous or non-aqueous liquid (for example, a solution or dispersion of at least one flavoring component in water or an organic liquid, such as alcohol or oil; or a mixture of water and a miscible liquid, such as alcohol or glycerin).Thus, for example, a plurality of such capsules can be incorporated into a substrate, and during product use, physical destruction of the capsule can cause the capsule to release the payload contained therein, resulting in the proper wetting of the components of the substrate formulation, as well as other functional benefits, such as enhanced taste. For example, as illustrated in FIG. 12, an appropriate number of capsules having an outer shell comprising a food-grade waxy substance and an inner payload comprising water may be incorporated into the substrate such that upon release of such capsules, sufficient water is released to provide the desired wetting effect to the substrate formulation.

[0180] In certain embodiments, the capsules may be coated to slow the degradation of the capsule outer shell or polymer matrix. For example, the capsules may be coated with a film-forming agent. Exemplary film-forming agents include hydroxypropyl cellulose, hydroxypropyl methylcellulose, modified starch, maltodextrin, carboxymethyl cellulose, alginate, carrageenan, xanthan, gellan, acacia gum, tragacanth gum, and combinations thereof.

[0181] In certain embodiments, and as illustrated in FIG. 13, rather than a core / shell structure, the capsule has a relatively homogeneous construction having a matrix of polymeric material (typically a polymeric material suitable for use as a shell material in a core / shell structure) and at least one additive dispersed within the polymeric matrix.

[0182] The capsules disclosed herein may be uniform or may vary in size, weight, and shape, depending on the desired properties of the substrate. Typical capsules are generally spherical in shape. However, suitable capsules may have other types of shapes, such as generally rectilinear, rectangular, elliptical, or oblong.

[0183] Capsules typically further include one or more stabilizers that secure the capsule's position within the substrate to prevent separation during shipping, storage, and handling. Stabilizers are protrusions from the outer surface of the capsule's body, which, in certain embodiments, can inhibit or limit capsule movement within the substrate. In certain embodiments, stabilizers can have the appearance of "wings" that extend partially or completely around the capsule body, or can otherwise provide lip, edge, or arm-like protrusions of uniform or irregular shape. The stabilizers can be formed of the same material as the capsule body (e.g., the outer shell or polymer matrix) or a different material. The stabilizers can be affixed anywhere suitable on the capsule and can vary in number and size. For example, a capsule can be spherical in shape and have two or more stabilizers along the x, y, z, or a combination thereof axis. In another example, a capsule can have one continuous stabilizer that extends circumferentially around the capsule. The stabilizer(s) can be shaped to have a first end and a second end, with the first end attached to the capsule and the second end extending from the capsule. The second end can be curved, straight, or a combination thereof. When two or more stabilizers are present, the stabilizers can be identical in shape or different in shape. The size of the stabilizer can vary based on the morphology of the remaining components of the substrate. For example, the size of the stabilizer can be wider and / or longer when combined with a filler having a relatively small particle size. Alternatively, the size of the stabilizer can be narrower or shorter when combined with a filler material having a larger particle size.

[0184] Exemplary capsules have diameters of at least about 0.1 mm, typically at least about 1 mm, often at least about 2 mm, and frequently at least about 3 mm, with exemplary ranges including about 0.1 mm to about 10 mm, or about 0.1 mm to about 1 mm, or about 0.1 mm to about 5 mm, or about 0.1 mm to about 3 mm. Exemplary stabilizers have lengths of at least 1 mm, typically at least 5 mm, often at least 10 mm, and frequently at least 20 mm. Exemplary weights of individual capsules weigh at least about 5 mg, often at least about 15 mg, and frequently at least about 25 mg. Exemplary stabilizers add at least about 0.1 mg, often at least about 0.5 mg, typically at least 1 mg, and frequently at least 2 mg of additional weight to individual capsules.

[0185] Alternatively, smaller capsules (i.e., microcapsules) can be used. Exemplary microcapsules can have diameters of less than about 100 microns, for example, microcapsules having diameters ranging from about 1 to about 40 microns, or from about 1 micron to about 20 microns, or from about 10 microns to about 100 microns.

[0186] The number of capsules incorporated into the substrate can vary depending on factors such as capsule size, the characteristics or properties of the additives in the payload, the desired properties of the substrate, etc. The number of capsules incorporated into the substrate can be greater than about 5, greater than about 10, greater than about 20, greater than about 40, or even greater than about 100. In certain embodiments, the number of capsules can be greater than about 500 or even greater than about 1,000, with exemplary ranges including from about 5 to about 500 or from about 10 to about 250.

[0187] The total weight of the capsules contained within the substrate can vary, but is typically greater than about 10 mg, often greater than about 20 mg, and may be greater than about 30 mg. The total weight of the capsules is typically less than about 200 mg, often less than about 100 mg, and may be less than about 50 mg.

[0188] The relative weight of the capsule in the substrate may vary. Typically, the dry weight of the tobacco in the substrate is greater than the weight contributed by the capsule component. However, the weight of the capsule component may range from about 5 percent to about 75 percent, often from about 20 percent to about 50 percent, of the combined dry weight of the capsule component and the substrate.

[0189] If desired, capsules of different sizes and / or types (e.g., different shell materials, different shell properties, e.g., shape or hardness, and / or different capsule-containing ingredients) can be incorporated into the product. In this manner, different capsules can be incorporated into the product to provide desired properties (e.g., flavor or other sensory effect) and / or to provide release of the encapsulated ingredients at different times during use of the product. For example, a first flavoring ingredient can be released from a first set of capsules upon initial introduction of the product into the user's mouth, while a second flavoring ingredient contained in a second set of capsules may not be released until a later time (e.g., the semi-dissolving coating of the second capsules takes longer to rupture than the coating of the first set of capsules).

[0190] The capsules of the present invention can be formed using any encapsulation technique known in the art. For example, capsules can be formed using any of a variety of chemical encapsulation techniques, such as solvent evaporation, solvent extraction, organic phase separation, interfacial polymerization, simple and complex coacervation, in-situ polymerization, liposome encapsulation, and nanoencapsulation. Alternatively, physical methods of encapsulation can be used, such as injection molding (including 3D printing), spheronization, granulation, extrusion, microfluidics, spray coating, pan coating, fluidized bed coating, annular jet coating, spinning disk atomization, spray cooling, spray drying, spray cryolysis, fixed nozzle coextrusion, centrifugal head coextrusion, or submerged nozzle coextrusion.

[0191] Coacervation is a colloidal phenomenon that begins with the dissolution of a colloid in a suitable solvent. Depending on the nature of the colloid, various changes can cause a decrease in the solubility of the colloid. As a result of this decrease, most of the colloid can separate into a new phase, thus forming a two-phase system with one high and one low colloid concentration. The dispersed colloid-rich phase appears as amorphous liquid droplets called coacervate droplets. Upon standing, these coalesce into a single colloid-rich, transparent, homogeneous liquid layer known as the coacervate layer, which can be deposited to produce the resulting capsule wall material.

[0192] Simple coacervation can be accomplished by mixing two colloidal dispersions, one of which has a high affinity for water, or can be induced by adding a strongly hydrophilic substance, such as alcohol or sodium sulfate. Water-soluble polymers are concentrated in water by the action of a water-miscible nonsolvent on the emerging polymer (e.g., gelatin) phase. Ethanol, acetone, dioxane, isopropanol, and propanol are exemplary solvents that can cause the separation of coacervates, such as gelatin, polyvinyl alcohol, or methyl cellulose. Phase separation can be achieved by adding an electrolyte, such as an inorganic salt, to an aqueous solution of a polymer, such as gelatin, polyvinyl alcohol, or carboxymethyl cellulose.

[0193] Complex coacervation can be induced in systems with two dispersed hydrophilic colloids of opposite charge. Neutralization of the overall positive charge on one of the colloids with a negative charge on the other is used to cause separation of a polymer-rich complex coacervate phase. The gelatin-gum arabic (gum acacia) system is one known complex coacervation system.

[0194] Organic phase separation is sometimes more simply called "water-in-oil" microencapsulation, where a polar core is dispersed in an oily or non-polar continuous medium, and the wall material then dissolves in this continuous medium.

[0195] The stabilizer for the capsule can be formed simultaneously with the capsule, or separately and fixedly attached. Similar to capsule formation, the stabilizer can be formed using any of a variety of chemical encapsulation techniques, such as solvent evaporation, solvent extraction, organic phase separation, interfacial polymerization, simple and complex coacervation, in-situ polymerization, liposome encapsulation, and nanoencapsulation. Alternatively, physical methods of stabilizer formation, such as injection molding, spheronization, granulation, extrusion, microfluidics, spray coating, pan coating, fluidized bed coating, annular jet coating, spinning disk atomization, spray cooling, spray drying, spray chilling, fixed nozzle coextrusion, centrifugal head coextrusion, or submerged nozzle coextrusion, can be used. In one embodiment, the stabilizer is formed with the capsule, resulting in a stabilizer that is a continuous extension of the capsule. In another embodiment, the stabilizer is formed separately from the capsule, resulting in an at least partially formed stabilizer that is attached to the outer wall of the at least partially formed capsule.

[0196] Regardless of the methodology utilized, the outer wall or shell materials, stabilizer materials, and solvents used to form the capsules of the present invention may vary and depend in part on the desired release characteristics of the capsule (e.g., moisture interaction, enzyme interaction, or heat-based release). Classes of materials typically used as wall or shell materials and stabilizer materials include proteins, polysaccharides, starches, waxes, fats, natural and synthetic polymers and resins. Exemplary materials for use in the encapsulation process used to form capsules include gelatin, acacia (gum arabic), polyvinyl acetate, potassium alginate, locust bean gum, potassium citrate, carrageenan, potassium polymetaphosphate, citric acid, potassium tripolyphosphate, dextrin, polyvinyl alcohol, povidone, dimethylpolysiloxane, dimethyl silicone, refined paraffin wax, ethyl cellulose, bleached shellac, modified food starch, sodium alginate, guar gum, sodium carboxymethylcellulose, hydroxypropyl cellulose, sodium citrate, hydroxypropylmethylcellulose, sodium ferrocyanide, sodium polyphosphate, locust bean gum, methylcellulose, sodium trimetaphosphate, methylethylcellulose, sodium tripolyphosphate, microcrystalline wax, tannic acid, petroleum waxes, terpene resins, tragacanth, polyethylene, xanthan gum, and polyethylene glycol.

[0197] In certain embodiments, when the capsule is intended to degrade via heating, the outer wall, stabilizer, or polymeric matrix material can include, for example, gelatin, genipin-crosslinked gelatin, polyhydroxyalkanoates (PHAs), polycaprolactone (PCL), pullulan, glucan, chitosan, ethylcellulose, and combinations thereof. It may be advantageous for the polymeric material to have a melting temperature higher than the temperature of the first puff of the aerosol delivery device (so that the encapsulated ingredient is released only after active use of the consumable containing the encapsulated ingredient). It may also be advantageous for the thermal decomposition temperature of the polymer to be higher than the maximum operating temperature of the device (to prevent the release of thermal decomposition products). For example, in certain embodiments, the outer wall, stabilizer, or polymeric matrix material has a melting point of about 100°C or higher, e.g., about 125°C or higher, or about 150°C or higher, or about 200°C or higher (e.g., a melting point range of about 100°C to about 350°C). Additionally, in certain embodiments, the outer wall, stabilizer, or polymer matrix material has a thermal decomposition temperature of about 250°C or greater, e.g., about 275°C or greater, or about 300°C or greater, or about 325°C or greater (e.g., a thermal decomposition temperature range of about 250°C to about 400°C).

[0198] In certain embodiments, the polymer matrix comprises ethyl cellulose, and the encapsulated material comprises one or more of stearic acid, glycerol, propylene glycol, or other aerosol-forming components (or combinations thereof), and one or more flavoring substances. Such combinations can be formed into capsules using spray-drying techniques, particularly using a spray-drying feedstream comprising ethanol or another alcohol as the solvent, at concentrations of 40-60% by weight of the aerosol-forming component (e.g., a combination of stearic acid and propylene glycol), 5-15% by weight of the ethyl cellulose, and 5-20% by weight of the flavoring substance, based on the total weight of the spray-drying solution.

[0199] In a further embodiment, the polymer matrix comprises ethyl cellulose that encapsulates one or more aerosol-forming components and / or one or more flavoring substances using granulation techniques. For example, ethyl cellulose can be combined with a solvent (e.g., ethanol) and an aerosol-forming component (e.g., propylene glycol) in a typical weight ratio of ethyl cellulose to aerosol-forming component of 1:3 to 3:1 (or 1:2 to 2:1 or 1:1), and granulated by application of mechanical force to form granules of the encapsulated aerosol-forming component.

[0200] In yet a further embodiment, spheronization techniques are used to create capsules comprising ethyl cellulose or PCL as a polymer matrix encapsulating one or more aerosol-forming ingredients and / or one or more flavoring substances. For example, capsules can be formed using such methods, where the concentration of ethyl cellulose or PCL within the capsule is about 15-25 wt. % and the concentration of the aerosol-forming ingredients and / or flavoring substances is about 25-75 wt. % based on the total weight of the capsule.

[0201] Substrate form The form of the substrate may vary. For example, the substrate component may be in the form of a powder, dust, particles, granules, pellets, flakes, strips, sheets, films, etc. In some embodiments, the component is in strip form, film form, paper form, or cast sheet form.

[0202] In some embodiments, the substrate is in the form of a cast sheet. In some embodiments, the cast sheet is a flat sheet. In some embodiments, the cast sheet has a thickness of about 0.015 mm to about 1.0 mm. Suitably, the thickness may range from about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm, e.g., 0.1-3 mm or 0.15-3 mm. Sheets having a thickness of 0.2 mm may be particularly suitable. Thicknesses defined herein refer to the thickness of the sheet. In some cases, the thickness of the sheet may vary by at most 25%, 20%, 15%, 10%, 5%, or 1%.

[0203] In some embodiments, the flat sheet form is layered, for example, a series of overlapping layers 130 of flat sheet form 120 illustrated in Figures 4-8. In some embodiments, the flat sheet form may be bundled, rolled, crimped, and / or otherwise collected. In some embodiments, the flat sheet form may be further reduced into a cut lug or strip for insertion into a substrate-containing segment of an aerosol delivery device. The flat sheet form may also be collected or wound into a rod for insertion into a substrate-containing segment of an aerosol delivery device. In some embodiments, the substrate is formed into a substantially cylindrical shape. In some embodiments, the flat sheet form may be a strip. While substrates in sheet form are advantageous in the present disclosure, other forms, such as beaded, strip, or particulate forms, may also be utilized in certain embodiments.

[0204] In some embodiments, the individual strips or pieces of substrate have a minimum thickness over their area of ​​about 0.015 mm. In some cases, the individual strips or pieces of substrate have a minimum thickness over their area of ​​about 0.05 mm or about 0.1 mm. In some cases, the individual strips or pieces of substrate have a maximum thickness over their area of ​​about 1.0 mm. In some cases, the individual strips or pieces of substrate have a maximum thickness over their area of ​​about 0.5 mm or about 0.3 mm.

[0205] In some examples, a substrate in sheet form can have a tensile strength of around 150 N / m to around 3000 N / m, for example, 150 N / m to 2500 N / m, or 150 N / m to 2000 N / m, or 200 N / m to 1700 N / m, or 250 N / m to 1500 N / m, or 200 N / m to 900 N / m. In some embodiments, the substrate can have a tensile strength of 150 N / m to 500 N / m, or 200 N / m to 400 N / m, or 200 N / m to 300 N / m, or about 250 N / m. Such tensile strengths may be particularly suitable for embodiments in which the substrate is formed into a sheet and then a strip and incorporated into an aerosol generating element.

[0206] In some embodiments, the substrate may have a tensile strength of 150 N / m to 3000 N / m, for example, 500 N / m to 1200 N / m, or 600 N / m to 900 N / m, or 700 N / m to 900 N / m, or around 800 N / m or more. In some examples, the substrate may have a tensile strength greater than 500 N / m, greater than 1000 N / m, or greater than 1500 N / m. Such tensile strengths may be particularly suitable for embodiments in which the substrate is included in an aerosol generation element in the form of a wound sheet, suitably a tube.

[0207] In some embodiments, the substrate is formed as a sheet and then cut into small pieces, such as particles or shreds. The substrate material in such form can be mixed with other materials, if desired, such as with shredded or particulate tobacco material or other non-tobacco substrate materials to form blends.

[0208] Preparation of cast sheets In some embodiments, a substrate can be produced in the form of a flat sheet using a cast sheet technique. The cast sheet generally comprises one or more fillers, one or more binders, optionally one or more aerosol-forming agents, and optionally an active ingredient, a flavoring substance, or both, each of which is described herein. For example, in some embodiments, a filler, at least a portion of the aerosol-forming material disclosed herein, and a binder can be blended together to form a slurry, which can then be cast onto a surface (e.g., a moving belt). The cast slurry can then be subjected to one or more drying and / or doctoring steps to obtain a cast sheet of relatively consistent thickness. Other examples of casting and papermaking techniques include U.S. Pat. No. 4,674,519 to Keritsis; 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. 5,099,864 to Sohn et al., the disclosures of which are incorporated herein by reference in their entireties. US Pat. No. 5,143,097 to Brinkley et al.; US Pat. No. 5,159,942 to Brinkley et al.; US Pat. No. 5,322,076 to Brinkley et al.; US Pat. No. 5,339,838 to Young et al.; US Pat. No. 5,377,698 to Litzinger et al.; US Pat. No. 5,501,237 to Young; and US Pat. No. 6,216,706 to Kumar. In some embodiments, the flat sheet form can be further reduced into a notched lug or strip for insertion into the substrate-containing segment of an aerosol delivery device. The cast sheet can also be collected or wound into a rod for insertion into the substrate-containing segment of an aerosol delivery device. The cast sheet can be glued or attached to a support.

[0209] The various components of the substrate can be contacted, combined, or mixed together using any mixing technique or device known in the art. Any mixing method that allows the substrate components to come into intimate contact can be used, such as a mixing device equipped with an impeller or other structure capable of stirring. Examples of mixing devices include casing drums, conditioning cylinders or drums, liquid spray devices, conical type blenders, ribbon blenders, mixers available from Littleford Day, Inc. under the names FKM130, FKM600, FKM1200, FKM2000, and FKM3000, Plough Share type mixer cylinders, Hobart mixers, etc. See also, for example, the types of methodologies described in US Pat. Nos. 4,148,325 to Solomon et al.; 6,510,855 to Korte et al.; and 6,834,654 to Williams, each of which is incorporated herein by reference. The manner and method for formulating the mixture will be apparent to those skilled in the art. See, for example, the types of methodologies described in U.S. Pat. Nos. 4,148,325 to Solomon et al.; 6,510,855 to Korte et al.; and 6,834,654 to Williams, 4,725,440 to Ridgway et al., and 6,077,524 to Bolder et al., each of which is incorporated herein by reference.

[0210] The sheet can optionally be dried to remove at least a portion of the liquid content (e.g., water). The final moisture content can be about 8 to about 21% moisture by weight on a wet basis. Additionally, flavoring substances, extracts, aerosol-forming materials, and the like can be added to the sheet after drying.

[0211] Filling the substrate In various embodiments, loading the substrate with the aerosol-forming material is achieved by impregnating the substrate with the aerosol-forming material during preparation of the substrate material, after formation, or both. In some embodiments, a slurry, e.g., a slurry used to prepare a cast sheet, contains the entire amount of aerosol-forming material. Alternatively or additionally, a portion of the aerosol-forming material may be added to the substrate after formation (e.g., one or more aerosol-forming materials may be sprayed onto the substrate material in sheet form or disposed within or on it). In some embodiments, the aerosol-forming material may also be impregnated into the substrate forming slurry or as a surface treatment. Methods for loading aerosol-forming material into a substrate portion are described in U.S. Pat. No. 9,974,334 to Dooly et al. and U.S. Pub. Pat. App. Nos. 2015 / 0313283 to Collett et al. and 2018 / 0279673 to Sebastian et al., the disclosures of which are incorporated herein by reference in their entireties. As one skilled in the art will recognize, multiple variations in the method for loading the substrate with the aerosol-forming material are possible depending on the particular substrate material, configuration, etc. Accordingly, any such modifications are contemplated herein.

[0212] In various embodiments, loading the substrate with capsules is accomplished by impregnating the substrate with the capsules after formation. In some embodiments, a portion of the capsules may be added to the substrate after formation (e.g., one or more capsules may be disposed in sheet form within or on the substrate material). In some embodiments, the capsules may also be impregnated into the substrate forming slurry or as a surface treatment. As one skilled in the art will recognize, multiple variations in methods for loading capsules into a substrate are possible depending on the particular substrate material, form, etc. Accordingly, any such variations are contemplated herein.

[0213] Aerosol-generating elements and aerosol delivery devices The substrate according to certain embodiments of the present disclosure can be used in an aerosol delivery device or an aerosol generating element thereof. Accordingly, a further exemplary embodiment of the present disclosure relates to an aerosol delivery device comprising: an aerosol generating element comprising the substrate disclosed herein; a heat source configured to heat an aerosol-forming material carried within the substrate portion to form an aerosol; and an aerosol path extending from the aerosol generating element to the mouth end of the aerosol delivery device. The individual components and construction of the aerosol generating element and the aerosol delivery device are provided herein below.

[0214] The aerosol-generating elements of certain exemplary aerosol delivery devices can provide many of the sensations of smoking a cigarette, cigar, or pipe (e.g., the ritual of inhaling and exhaling, the type of taste or flavor, the organoleptic effect, the physical feel, the ritual of use, visual cues, such as those provided by a visible aerosol, etc.) obtained by lighting and burning tobacco (and thus inhaling tobacco smoke), without any substantial degree of combustion of any of its components. For example, a user of an aerosol delivery device according to some exemplary embodiments of the present disclosure can hold and use the components in much the same way as a smoker uses a traditional type of smoking article, and can utilize one end of the piece to inhale the aerosol generated by the piece, taking or drawing puffs at selected time intervals, etc.

[0215] Although the present system is generally described herein in terms of embodiments relating to aerosol delivery devices and / or aerosol generating elements, e.g., so-called "e-cigarettes" or "heat-not-burn tobacco products," it should be understood that the mechanisms, components, features, and methods may be embodied in many different forms and associated with a variety of articles. For example, the description provided herein may be utilized in conjunction with traditional smoking articles (e.g., cigarettes, cigars, pipes, etc.), heated tobacco products, and associated packaging embodiments for any of the products disclosed herein. Accordingly, it should be understood that the description of the mechanisms, components, features, and methods disclosed herein, in terms of embodiments relating to aerosol delivery devices, is discussed by way of example only and may be embodied and used in a variety of other products and methods.

[0216] The aerosol delivery devices and / or aerosol-generating elements of the present disclosure can also be characterized as vapor-product or pharmaceutical delivery articles. Thus, such articles or devices can also be adapted to provide one or more substances (e.g., flavors and / or pharmaceutically active ingredients) in an inhalable form or state. For example, the inhalable substance may be substantially in vapor form (i.e., a substance in the gas phase at a temperature below its critical point). Alternatively, the inhalable substance may be in the form of an aerosol (i.e., a suspension of fine solid particles or liquid droplets in a gas). For brevity, the term "aerosol," as used herein, is intended to include vapors, gases, and aerosols in any form or type suitable for human inhalation, regardless of whether they are visible and in a form that can be considered similar to smoke. The physical form of the inhalable substance is not necessarily limited by the nature of the device of the present invention; rather, whether it exists in a vapor or aerosol state may depend on the properties of the medium and the inhalable substance itself. In some embodiments, the terms "vapor" and "aerosol" may be interchangeable. Thus, for clarity, the terms "vapor" and "aerosol" are considered interchangeable when used to describe aspects of the present disclosure, unless otherwise stated.

[0217] More specific formats, configurations, and arrangements of the various substrate materials, aerosol generating elements, and components within the aerosol delivery devices of the present disclosure will become apparent in light of the further disclosure provided hereinafter. Furthermore, the selection of various aerosol delivery device components is recognized in light of commercially available electronic aerosol delivery devices. Furthermore, the arrangement of components within the aerosol delivery device is also recognized in light of commercially available electronic aerosol delivery devices.

[0218] Substrates according to certain embodiments of the present disclosure can be used in aerosol-generating elements (e.g., segments) of heated-not-burn (HNB) devices, which use an ignitable heat source to heat a material (generally without burning the material to any significant extent) to form an inhalable substance (e.g., a carbon-heated tobacco product). The material is typically heated without burning the material to any significant extent. See, for example, U.S. Patent Application Publication No. 2017 / 0065000 to Sears et al.; U.S. Patent Application Publication No. 2015 / 0157052 to Ademe et al.; U.S. Patent No. 10,314,330 to Conner et al.; U.S. Patent No. 9,345,268 to Stone et al.; U.S. Patent No. 9,149,072 to Conner et al.; and U.S. Patent Nos. 5,105,831 and 5,042,509, both to Banerjee et al., each of which is incorporated herein by reference. The components of such systems have the form of articles small enough to be considered handheld devices, i.e., use of the components of certain exemplary aerosol delivery devices does not result in the production of smoke, in the sense that the aerosol is produced primarily from the by-products of tobacco combustion or pyrolysis, but rather use of these systems results in the production of vapor from the volatilization or evaporation of certain components incorporated therein.

[0219] Thus, in some embodiments, the aerosol generating element of the present disclosure may generally include an ignitable heat source configured to heat a substrate material disclosed herein and aerosolize an aerosol-forming material associated with the substrate material to form an inhalable substance. At least a portion of the substrate material and / or heat source may be enclosed in an outer wrapping or encasement, casing, component, module, member, or the like. The overall design of the enclosure may vary, as may the format or configuration of the enclosure, which defines the overall size and shape of the aerosol generating element. While other configurations are possible, in some aspects it may be desirable for the overall design, size, and / or shape of these embodiments to be similar to that of a traditional cigarette or cigar.

[0220] Substrates according to certain embodiments of the present disclosure can be used in the aerosol-generating element of an aerosol delivery device that uses electrical energy to heat the substrate material disclosed herein and aerosolize an aerosol-forming material associated with the substrate material to form an inhalable substance (e.g., an electrically heated tobacco product). In some exemplary embodiments, the aerosol delivery device can be characterized as an electronic cigarette. Thus, in some embodiments, the aerosol delivery device of the present disclosure can include some combination of a power source (e.g., a power supply), at least one control component (e.g., a means for activating, controlling, regulating, and terminating the power for heat generation by controlling, individually or as part of a microcontroller, the current from the power source to other components of the article, e.g., a microprocessor), a heat source (e.g., an electrically resistive heating element or other component and / or an inductive coil or other associated component and / or one or more radiant heating elements), and an aerosol-generating element comprising a substrate portion disclosed herein, which is capable of generating an aerosol upon application of sufficient heat. It should be noted that one or more of the components described above can be physically combined. For example, in certain embodiments, conductive heater traces can be printed onto the surface of a substrate material as described herein (e.g., cellulose or film) using a conductive ink such that the heater traces can be powered by a power source and used as resistive heating elements. Exemplary conductive inks include graphene inks and inks containing various metals, such as inks containing silver, gold, palladium, platinum, and alloys or other combinations thereof (e.g., silver-palladium or silver-platinum inks), which can be printed onto a surface using processes such as gravure printing, flexography, offset printing, screen printing, inkjet printing, or other suitable printing methods.

[0221] In various embodiments, several of these components can comprise an exterior body or shell, which in some embodiments can be referred to as a housing. The overall design of the exterior body or shell can vary, and the format or configuration of the exterior body can vary, which can define the overall size and shape of the aerosol delivery device. In some embodiments, the elongated body can be formed from a single housing, resembling the shape of a cigarette or cigar, or the elongated housing can be formed from two or more separable bodies, although other configurations are possible. For example, the aerosol delivery device can include an elongated shell or body that is substantially tubular in shape and thus can resemble the shape of a traditional cigarette or cigar. In one example, all of the components of the aerosol delivery device are contained within a single housing or body. In other embodiments, the aerosol delivery device can include two or more joined, separable housings. For example, the aerosol delivery device may have a control unit at one end that includes a housing containing one or more reusable components (e.g., an accumulator, e.g., a rechargeable battery and / or a rechargeable supercapacitor and various electronics for controlling the operation of the item) and at the other end an outer casing or shell containing a disposable portion (e.g., a disposable flavor-containing aerosol generating element) removably connectable thereto.

[0222] Aerosol generating elements and aerosol delivery devices that include a substrate disclosed herein and use heat from combustion or electrical energy can further include additional materials, e.g., in admixture with the substrate, e.g., additional tobacco materials, tobacco-derived materials, etc., also referred to herein as "aerosol-generating materials." Such aerosol generating elements can also be referred to herein as "consumables," which means articles that include or consist of a substrate described herein, some or all of which are intended to be consumed by a user during use.

[0223] In some embodiments, the aerosol-generating element comprises a substrate disclosed herein in the form of a sheet or in the form of a strip. In some embodiments, the aerosol-generating element further comprises an additional aerosol-generating material, such as a tobacco material or a tobacco-derived material. In some embodiments, the additional aerosol-generating material is tobacco material in the form of strips or particles, and is blended with the substrate. In some embodiments, both the substrate and the tobacco material are in the form of strips. In some embodiments, the substrate is present in a layered form comprising multiple sheets (layers) of substrate.

[0224] In some embodiments, the aerosol generating element further comprises a support. In some embodiments, the substrate is affixed or adhered to the support. In some embodiments, the support is planar. A non-limiting embodiment of an aerosol generating element comprising a support and having a substrate affixed or adhered thereto is illustrated in Figure 1. With reference to Figure 1, the aerosol generating element 10 comprises a support 20 and a substrate 30 disposed thereon.

[0225] The support 20 can be at least partially porous in the area of ​​its surface that abuts the substrate 30. Conversely, the surface of the support 20 facing away from the substrate 30 can be placed in contact with a heat source as described herein. In some embodiments, the support 20 can be a laminate structure. For example, the support 20 can include a cardboard-backed foil, with the cardboard layer abutting the substrate 30. The foil backing is substantially impermeable, providing aerosol flow path control. The metal foil backing can also function to conduct heat to the substrate 30. In some embodiments, the foil layer of the cardboard-backed foil abuts the substrate 30. The foil is substantially impermeable, thereby preventing moisture in the substrate 30 from being absorbed into the cardboard, which could weaken its structural integrity. In some embodiments, the support 20 is formed from or includes a metal foil, such as aluminum foil. The metal support can allow for better conduction of thermal energy to the substrate. Additionally or alternatively, the metal foil can function as a susceptor in an induction heating system. In certain embodiments, the support 20 includes a metal foil layer and a support layer, such as cardboard. In these embodiments, the metal foil layer can have a thickness of less than 20 μm, for example, from about 1 μm to about 10 μm, suitably about 5 μm.

[0226] Aerosol generating elements and aerosol delivery devices that include the substrates disclosed herein and that use heat from combustion or electrical energy to provide an aerosol are further described herein below with reference to Figures 2-8.

[0227] In this regard, FIG. 2 illustrates an aerosol delivery device 100 according to an exemplary embodiment of the present disclosure. The aerosol delivery device 100 can include a controller 102 and an aerosol generating element 104. In some embodiments, the aerosol generating element is configured for use with a conductive and / or inductive heat source to heat a substrate material to form an aerosol. In various embodiments, the conductive heat source can include a heating assembly including a resistive heating element. The resistive heating element can be configured to generate heat when an electric current is induced therethrough. Conductive materials useful as resistive heating elements can be materials that have low mass, low density, and moderate resistivity and are thermally stable at temperatures applied during use. Useful heating elements heat and cool rapidly, thereby providing efficient use of energy. Rapid heating of the element can be beneficial for providing almost instantaneous volatilization of the aerosol-forming material in its vicinity. Rapid cooling prevents substantial volatilization (and thus waste) of the aerosol-forming material during periods when aerosol formation is not desired. Such heating elements can also allow for relatively precise control of the temperature range applied to the aerosol-forming material, especially when time-based current control is utilized. Useful conductive materials are typically chemically non-reactive with the materials being heated (e.g., the aerosol-forming material and other inhalable substance materials), thereby avoiding adverse effects on 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 can be particularly useful. Various different materials can be blended to achieve desired properties of resistivity, mass, and thermal conductivity. In certain embodiments, metals that can be utilized include, for example, nickel, chromium, nickel-chromium alloys (e.g., nichrome), and steel.Materials that may be useful for providing resistive heating are disclosed in US Pat. No. 5,060,671 to Counts et al.; US Pat. No. 5,093,894 to Deevi et al.; US Pat. No. 5,224,498 to Deevi et al.; Sprinkel et al.; the disclosures of which are incorporated herein by reference in their entireties. No. 5,228,460 to Jr. et al.; No. 5,322,075 to Deevi et al.; No. 5,353,813 to Deevi et al.; No. 5,468,936 to Deevi et al.; No. 5,498,850 to Das; No. 5,659,656 to Das; No. 5,498,855 to Deevi et al.; No. 5,530,225 to Hajaligol; No. 5,665,262 to Hajaligol; No. 5,573,692 to Das et al.; and No. 5,591,368 to Fleischhauer et al.

[0228] In various embodiments, the heating element may be provided in various forms, such as a foil, foam, mesh, hollow ball, half-ball, disk, spiral, fiber, wire, film, thread, strip, ribbon, or cylinder. Such heating elements often comprise a metallic material and are designed 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 located on the control device 102, the cylinder being constructed of one or more conductive materials, including, but not limited to, copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, carbon (e.g., graphite), or any combination thereof. In various embodiments, the heating element may also be coated with any of these or other conductive materials. The heating element may be located proximal to the engagement end of the control device 102 and configured to substantially surround a portion of the heated end 106 of the aerosol generation element 104, including the substrate portion 110. In this manner, the heating element can be located proximate to the substrate portion 110 of the aerosol generating element 104 when the aerosol generating element 104 is inserted into the control device 102. In other examples, at least a portion of the heating element can penetrate at least a portion of the aerosol generating element (e.g., one or more protrusions and / or spikes that penetrate the aerosol generating element) when the aerosol generating element is inserted into the control device. Note that in some embodiments, the heating element can comprise a cylinder, but in other embodiments, the heating element can take various forms and, in some embodiments, can directly contact and / or penetrate the substrate portion.

[0229] In addition to being designed for use with a conductive heat source as described above, the aerosol generation element disclosed herein may also be designed for use with an inductive heat source that heats a substrate portion to form an aerosol. In various embodiments, the inductive heat source can include a resonant transformer, which can include a resonant transmitter and a resonant receiver (e.g., a susceptor). In some embodiments, the resonant transmitter and resonant receiver can be located in the control device 102. In other embodiments, the resonant receiver, or a portion thereof, can be located in the aerosol generation element 104. For example, in some embodiments, the control device 102 can include a resonant transmitter, which can include, for example, a foil material, a coil, a cylinder, or other structure configured to generate an oscillating magnetic field, and a resonant receiver, which can include one or more protrusions extending to or surrounded by the substrate portion. In some embodiments, the aerosol generation element is in intimate contact with the resonant receiver.

[0230] In other embodiments, the resonant transmitter can include a helical coil configured to surround the cavity that receives the aerosol generation element, particularly the substrate portion of the aerosol generation element. In some embodiments, the helical coil can be located between the outer wall of the device and the receiving cavity. In one embodiment, the coil winding can have a circular cross-sectional shape. However, in other embodiments, the coil winding can have a variety of other cross-sectional shapes, including, but not limited to, oval, rectangular, L-shaped, T-shaped, triangular, and combinations thereof. In another embodiment, a pin can extend into a portion of the receiving cavity, and the pin can include a coil structure, for example, around or within the pin, thereby including a resonant transmitter. In various embodiments, the aerosol generation element can be received in the receiving cavity, and one or more components of the aerosol generation element can function as a resonant receiver. In some embodiments, the aerosol generation element includes a resonant receiver. Other possible resonant transformer components, including resonant transmitters and resonant receivers, are described in US Pat. App. Pub. No. 2019 / 0124979 to Sebastian et al., which is incorporated herein by reference in its entirety.

[0231] In various embodiments, the aerosol generation element 104 and the control device 102 may be permanently or separably aligned in operative relationship. In this regard, Figure 2 illustrates the aerosol delivery device 100 in a coupled configuration, while Figure 2 illustrates the aerosol delivery device 100 in a decoupled configuration. The aerosol generation element 104 can be coupled with the control device 102 by various mechanisms, providing a threaded engagement, a press-fit engagement, an interference fit, a slip fit, a magnetic engagement, etc.

[0232] 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-like, substantially tubular, or substantially cylindrical. In the embodiment of FIGS. 2-3 , the device 100 has a substantially circular cross-section. However, other cross-sectional shapes (e.g., oval, square, triangular, etc.) are also encompassed by the present disclosure. For example, in some embodiments, one or both of the control device 102 or the aerosol generation element 104 (and / or any subcomponents) can have a substantially rectangular shape, such as a substantially rectangular cubic shape (e.g., a shape similar to a USB flash drive). In other embodiments, one or both of the control device 102 or the aerosol generation element 104 (and / or any subcomponents) can have other handheld shapes. For example, in some embodiments, the control device 102 can have a small box shape, various podmod shapes, or a fob shape. Thus, such language describing the physical form of an article can also apply to its individual components, including the control device 102 and the aerosol-generating element 104.

[0233] The arrangement of components within the aerosol delivery devices of the present disclosure may vary across various embodiments. In some embodiments, the substrate portion may be positioned proximate to the heat source to maximize delivery of the aerosol to the user. However, other configurations are not excluded. Generally, the heat source may be positioned sufficiently close to the substrate portion so that heat from the heat source can volatilize the substrate portion (e.g., any aerosol-forming material therein) and form an aerosol for delivery to the user. When the heat source heats the substrate portion, an aerosol is formed, released, or generated in a physical form suitable for inhalation by the consumer. It should be noted that the foregoing terms are intended to be interchangeable, such that references to release, releasing, releases, or released include form or generate, forming or generating, forms or generates, and formed or generated. Specifically, the inhalable substance is released in the form of a vapor or an aerosol or a mixture thereof, and such terms are also used interchangeably herein, except where otherwise specified.

[0234] As described above, various embodiments of the aerosol delivery device 100 can incorporate a battery and / or other power source to provide a sufficient current flow to provide various functionality to the aerosol delivery device, such as powering a heat source, powering a control system, and powering an indicator. As discussed in more detail below, the power source can take various forms. The power source can deliver sufficient power to rapidly activate the heat source, resulting in aerosol formation, and power the aerosol delivery device through use for a desired period of time. In some embodiments, the power source is sized to fit conveniently within the aerosol delivery device, allowing for easy handling. Examples of useful power sources include lithium-ion batteries, which are typically rechargeable (e.g., rechargeable lithium-manganese dioxide batteries). In particular, lithium polymer batteries can be used, as they can offer greater safety than such batteries. Other types of batteries, such as N50-AAACADNICA nickel-cadmium cells, can also be used. Furthermore, exemplary power sources are lightweight enough so as not to impair the desired smoking experience. Some examples of possible power sources are described in US Pat. No. 9,484,155 to Peckerar et al. and US Pat. App. Pub. No. 2017 / 0112191 to Sur et al., the disclosures of each of which are incorporated herein by reference in their entirety.

[0235] In certain embodiments, one or both of the control device 102 and the aerosol generation element 104 can be referred to as disposable or reusable. For example, the control device 102 can have a replaceable or rechargeable battery, a solid-state battery, a thin-film solid-state battery, a rechargeable supercapacitor, etc., and can therefore be combined with any type of recharging technology, including connection to a wall charger, a car charger (i.e., a cigarette lighter case), and a computer, e.g., a solar cell (sometimes called a solar cell) or solar panel photovoltaic cell via a Universal Serial Bus (USB) cable or connector (e.g., USB 2.0, 3.0, 3.1, USB Type-C), a wireless charger, e.g., a charger using inductive wireless charging (e.g., including wireless charging according to the Wireless Power Consortium (WPC) Qi wireless charging standard), or a wireless radio frequency (RF)-based charger. An example of an inductive wireless charging system is described in US Pat. App. Pub. No. 2017 / 0112196 to Sur et al., which is incorporated herein by reference in its entirety. Additionally, in some embodiments, the aerosol generating element 104 can include a single-use device. Single-use components for use in a control device are disclosed in U.S. Pat. No. 8,910,639 to Chang et al., which is incorporated herein by reference in its entirety.

[0236] In a further embodiment, the power source can also include a capacitor. The capacitor can discharge faster than a battery and can be charged during a puff, allowing the battery to discharge into the capacitor at a slower rate than if it were used to directly power the heat source. For example, a supercapacitor, such as an electric double-layer capacitor (EDLC), can be used separately from or in combination with a battery. When used alone, the supercapacitor can be recharged before each use of the article. Thus, the device can also include a charger component that can be attached to the smoking article between uses to replenish the supercapacitor.

[0237] Additional components can be utilized in the aerosol delivery devices of the present disclosure. For example, the aerosol delivery device can include a flow sensor that is sensitive to either a change in pressure or a change in airflow when a consumer draws on the article (e.g., a puff-activated switch). Other possible current activation / deactivation mechanisms can include a temperature-activated on / off switch or a lip-pressure-activated switch. An exemplary mechanism that can provide such puff-activation capability includes the Model 163PC01D36 silicon sensor, manufactured by the MicroSwitch division of Honeywell, Inc., Freeport, Ill. Representative flow sensors, current regulating components, and other current control components, including various microcontrollers, sensors, and switches, for aerosol delivery devices are described in U.S. Pat. No. 4,735,217 to Gerth et al., U.S. Pat. Nos. 4,922,901, 4,947,874, and 4,947,875, all to Brooks et al., U.S. Pat. No. 5,372,148 to McCafferty et al., U.S. Pat. No. 6,040,560 to Fleischhauer et al., U.S. Pat. No. 7,040,314 to Nguyen et al., and U.S. Pat. No. 8,205,622 to Pan, all of which are incorporated herein by reference in their entirety. See also the control scheme described in U.S. Pat. No. 9,423,152 to Ampolini et al., which is incorporated herein by reference in its entirety.

[0238] In another example, the aerosol delivery device can include a first conductive surface configured to contact a first body part of a user holding the device and a second conductive surface conductively separated from the first conductive surface and configured to contact a second body part of the user. Thus, when the aerosol delivery device detects a change in conductivity between the first and second conductive surfaces, the vaporizer activates to vaporize the substance so that the vapor can be inhaled by the user-held unit. The first and second body parts can be the lips or hands. The two conductive surfaces can also be used to charge a battery contained within the personal vaporizer unit. The two conductive surfaces can also form a connector or part of a connector that can be used to output data stored in the memory. See U.S. Pat. No. 9,861,773 to Terry et al., incorporated herein by reference in its entirety.

[0239] Additionally, US Pat. No. 5,154,192 to Sprinkel et al. discloses an indicator for a smoking article. US Pat. No. 5,261,424 to Sprinkel, Jr. discloses a piezoelectric sensor that can be associated with the mouth end of a device that detects lip activity associated with inhaling a user's lips and then triggers heating of the heating device. US Pat. No. 5,372,148 to McCafferty et al. discloses a puff sensor for controlling the flow of energy to a heat load array in response to a pressure drop through a mouthpiece. US Pat. No. 5,967,148 to Harris et al. discloses a receptacle in a smoking device that includes an identifier that detects non-uniformity in the infrared transmittance of an inserted ingredient and a controller that executes a detection routine when an ingredient is inserted into the receptacle. US Pat. No. 6,040,560 to Fleischhauer et al. describes a defined executable power cycle with multiple differential phases. U.S. Pat. No. 5,934,289 to Watkins et al. discloses photonic-optronic components. U.S. Pat. No. 5,954,979 to Counts et al. discloses means for modifying the resistance to draw through a smoking device. U.S. Pat. No. 6,803,545 to Blake et al. discloses specific battery configurations for use in smoking devices. U.S. Pat. No. 7,293,565 to Griffen et al. discloses various charging systems for use with smoking devices. U.S. Pat. No. 8,402,976 to Fernando et al. discloses computer interface means for smoking devices that facilitate charging and allow computer control of the device. U.S. Pat. No. 8,689,804 to Fernando et al. discloses an identification system for smoking devices. PCT Pat. App. Pub. No. WO2010 / 003480 to Flick discloses a fluid flow detection system for indicating puffs in an aerosol generating system. All of the foregoing disclosures are incorporated herein by reference in their entirety.

[0240] Further examples of components related to electronic aerosol delivery articles and disclosed materials or components that can be used in the devices of the present invention include U.S. Pat. No. 4,735,217 to Gerth et al.; U.S. Pat. No. 5,249,586 to Morgan et al.; U.S. Pat. No. 5,666,977 to Higgins et al.; U.S. Pat. No. 6,053,176 to Adams et al.; U.S. Pat. No. 6,164,287 to White; U.S. Pat. No. 6,196,218 to Voges; U.S. Pat. No. 6,810,883 to Felter et al.; U.S. Pat. No. 6,854,461 to Nichols; U.S. Pat. No. 7,832,410 to Hon; and U.S. Pat. No. 7,511,512 to Kobayashi, each of which is incorporated herein by reference in its entirety. 3,253; Hamano, U.S. Pat. No. 7,896,006; Shayan, U.S. Pat. No. 6,772,756; Hon, U.S. Pat. Nos. 8,156,944 and 8,375,957; Thorens et al., U.S. Pat. No. 8,794,231; Oglesby et al., U.S. Pat. No. 8,851,083; Monsees et al., U.S. Pat. No. 8,915 ,254 and 8,925,555; US Pat. No. 9,220,302 to DePiano et al.; US Pat. App. Pub. Nos. 2006 / 0196518 and 2009 / 0188490 to Hon; US Pat. App. Pub. No. 2010 / 0024834 to Oglesby et al.; US Pat. App. Pub. No. 2010 / 0307518 to Wang; PCT Pat. App. Pub. No. WO2010 / 091593 to Hon; and PCT Pat. App. Pub. No. WO2013 / 089551 to Foo. Additionally, US Pat. App. Pub. No. 2017 / 0099877 to Worm et al. discloses capsules that may be included in aerosol delivery devices and fob configurations for aerosol delivery devices, and is incorporated herein by reference in its entirety.The various materials disclosed by the aforementioned documents may be incorporated into the devices of the present invention in various embodiments, and all of the foregoing disclosures are incorporated herein by reference in their entirety.

[0241] Referring to FIG. 3 , in the illustrated embodiment, the aerosol-generating element 104 includes a heated end 106 (designed to be inserted into the control device 102) and a mouth end 108 (where a user draws to create an aerosol). At least a portion of the heated end 106 includes a substrate portion 110. In some embodiments, the substrate portions 110 each include a substrate comprising an aerosol-forming material as disclosed herein. In various embodiments, the aerosol-generating element 104, or a portion thereof, may be packaged in an outer overwrap material 112. In various embodiments, the mouth end 108 of the aerosol-generating element 104 may include a filter 114, which may be made of, for example, cellulose acetate or a polypropylene material. The filter 114 may also or alternatively contain strands of tobacco-containing material, such as those 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 can increase the structural integrity of the mouth end of the aerosol generation element 104 and / or provide filtering capabilities, if desired, and / or provide resistance to draw. In some embodiments, the filter can include separate segments. For example, some embodiments can include a segment that provides filtering, a segment that provides resistance to draw, a hollow segment that provides space for cooling the aerosol, a segment that provides greater structural integrity, other filter segments, and any one or any combination of the above.

[0242] In some embodiments, the material of the outer overwrap 112 can include a material that resists heat transfer, which can include paper or other fibrous materials, such as cellulosic materials. The outer overwrap material can also include at least one filler material embedded or dispersed within the fibrous material. In various embodiments, the filler material can have the form of water-insoluble particles. Additionally, the filler material can incorporate inorganic components. In various embodiments, the outer overwrap can be formed of multiple layers, such as an underlying, bulk, and top layer, such as a typical cigarette wrapper paper. Such materials can include, for example, lightweight "rag fibers," such as flax, hemp, sisal, rice straw, and / or esparto. The outer overwrap can also include materials commonly used in conventional cigarette filter elements, such as cellulose acetate. Additionally, the excess length of the outer overwrap at the mouth end 108 of the aerosol-generating element can function simply to separate the substrate portion 110 from the consumer's mouth, or to provide space for positioning a filter material as described below, or to affect inhalation of the article, or to affect the flow characteristics of vapor or aerosol desorbing from the device during inhalation. Further discussion of configurations for outer overwrap materials that can be used in the present disclosure can be found in U.S. Pat. No. 9,078,473 to Worm et al., which is incorporated herein by reference in its entirety.

[0243] In some embodiments, the aerosol generating element and the control device are typically provided together as a complete aerosol delivery article, although the components may be provided separately. For example, the present disclosure also encompasses disposable units for use with reusable smoking articles or reusable pharmaceutical delivery articles. In certain embodiments, such disposable units (which may be aerosol generating elements as illustrated in the accompanying figures) may include a substantially tubular-shaped body having a heated end configured to engage with a reusable aerosol delivery article, opposing mouth ends configured to allow delivery of a substance for inhalation to a consumer, and a wall having outer and inner surfaces defining an interior space. Various embodiments of aerosol generating elements (or cartridges) are described in U.S. Pat. No. 9,078,473 to Worm et al., the entire contents of which are incorporated herein by reference.

[0244] Although some figures described herein depict the controller and aerosol generating element in operative relationship, it is understood that the controller and aerosol generating element can exist as separate devices, and therefore, any discussion provided elsewhere herein relating to combined components should also be understood to apply to the controller and aerosol generating element as individual and separate components.

[0245] In another aspect, the present disclosure may be directed to a kit providing various components described herein. For example, the kit may include a control device having one or more aerosol generating elements. The kit may further include a control device having one or more charging components. The kit may further include a control device having one or more batteries. The kit may further include a control device having one or more aerosol generating elements and one or more charging components and / or one or more batteries. In further embodiments, the kit may include multiple aerosol generating elements. The kit may further include multiple aerosol generating elements and one or more batteries and / or one or more charging components. In the above embodiments, the aerosol generating elements or the control device may include a heating element therein. The kit of the present invention may further include a case (or other packaging, shipping, or storage component) for housing one or more additional kit components. The case may be a reusable rigid or flexible container. Furthermore, the case may simply be a box or other packaging structure.

[0246] 4 illustrates a schematic perspective view of an aerosol generating element according to an exemplary embodiment of the present disclosure. In particular, FIG. 4 illustrates an aerosol generating element 104 having a substrate portion 110 including a series of overlapping layers 130 of substrate in sheet form 120 and capsules 138. Referring to the above, in the illustrated embodiment, the substrate sheet 120 includes a film or layer as disclosed herein. In various embodiments, the term "overlapping layers" can also include bundled, rolled, crimped, and / or otherwise assembled layers where individual layers may not be apparent.

[0247] For example, FIGS. 7-8 illustrate schematic cross-sectional views of a substrate portion 110 of an aerosol generation element 104 according to exemplary embodiments of the present disclosure. In particular, FIG. 7 illustrates the substrate portion 110, which includes a series of overlapping layers 130 of substrate sheets 120. In the embodiment shown in FIG. 7, a capsule 138 is disposed within the substrate layer 130. In the embodiment shown in FIG. 8, a plurality of capsules 138, each including stabilizers 140 in the form of wings, are disposed within the substrate layer 130. The capsules are further illustrated in FIGS. 9-11. In the embodiment shown, at least a portion of the overlapping layers 130 are substantially surrounded around their outer surfaces by a first cover layer 132. In various embodiments, the first cover layer 132 can be constructed via a casting process, such as that described in U.S. Pat. No. 5,697,385 to Seymour et al., the disclosure of which is incorporated herein by reference in its entirety.

[0248] 12-13 illustrate diagrams of capsules according to exemplary embodiments of the present disclosure. In particular, FIG. 12 illustrates a capsule including an outer shell 310, typically composed of a polymeric material and an inner payload. In this embodiment, the inner payload includes an optional second polymeric material 312 and an encapsulated additive 314. The polymeric materials of the outer shell and the inner payload are typically different and can be selected to provide different release characteristics (e.g., due to differences in melting points or thermal decomposition temperatures). In FIG. 13, the capsule is illustrated as having a homogeneous construction including a polymeric matrix 412 encapsulating a dispersed additive 410.

[0249] 7-8 , in the illustrated embodiment, at least a portion of overlapping layer 130 and first cover layer 132 are substantially surrounded on their outer surfaces by an optional second cover layer 134. While the composition of second cover layer 134 can vary, in the illustrated embodiment, second cover layer 134 comprises a metal foil material, e.g., aluminum foil material. In other embodiments, the second cover layer can comprise other materials, including, 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 an optional third cover layer 136, which is substantially surrounded on its outer surfaces by overlapping layer 130, first cover layer 132, and second cover layer 134. In the illustrated embodiment, third cover layer 136 comprises a paper material, e.g., conventional cigarette paper. In various embodiments, the paper material can include rag fibers, for example, non-wood plant fibers, and can include flax, hemp, sisal, rice straw, and / or esparto fibers.

[0250] In various embodiments, other components may be present between the substrate portion 110 and the mouth end 108 of the aerosol-generating element 104. For example, in some embodiments, one or any combination of the following may be disposed between the substrate portion 110 and the mouth end 108 of the aerosol-generating element 104: an air gap; a hollow 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.

[0251] Figure 5 illustrates a perspective view of an aerosol generating element according to another exemplary embodiment of the present disclosure, and Figure 6 illustrates a perspective view of the aerosol generating element of Figure 7 or 8 with the outer packaging removed. In the illustrated embodiment, the aerosol generating element 200 of the illustrated embodiment includes a heat source 204, a substrate portion 210, an intermediate component 208, and a filter 212. In the illustrated embodiment, the intermediate component 208 and the filter 212 together include a mouthpiece 214.

[0252] In various embodiments, the heat source 204 may be designed 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 carbonaceous material. In other embodiments, the heat source 204 may have a different shape, for example, a prismatic shape with a triangular, cubic, or hexagonal cross section. Carbonaceous materials generally have a high carbon content. Certain exemplary carbonaceous materials may be composed primarily of carbon and / or may have a carbon content, typically greater than about 60 percent, typically greater than about 70 percent, often greater than about 80 percent, and frequently greater than about 90 percent, on a dry weight basis.

[0253] In some cases, heat source 204 can incorporate elements other than combustible carbonaceous material (e.g., tobacco components, e.g., powdered tobacco or tobacco extract; flavoring agents; salts, e.g., sodium chloride, potassium chloride, and sodium carbonate; thermally stable graphite fibers; iron oxide powder; glass filaments; powdered calcium carbonate; alumina granules; an ammonia source, e.g., an ammonia salt; a binder, e.g., guar gum, ammonium alginate, and sodium alginate; and / or a phase change material for reducing the temperature of the heat source, as described hereinabove). While the specific dimensions of applicable heat sources can vary, in some embodiments, heat source 204 can have a length in the range of approximately 7 mm to approximately 20 mm, inclusive, and in some embodiments, approximately 17 mm, and an overall diameter in the range of approximately 3 mm to approximately 8 mm, inclusive, and in some embodiments, approximately 4.8 mm (and in some embodiments, approximately 7 mm). In other embodiments, the heat source can be constructed in various ways, but in the embodiment shown, the heat source 204 is extruded or mixed using crushed or powdered carbonaceous material, with a dry weight of approximately 0.5 g / cm 3 Larger, often around 0.7 g / cm 3 Larger, often around 1g / cm 3and 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 comprises an extruded monolithic carbonaceous material having a generally cylindrical shape with a plurality of grooves 216 extending longitudinally from a first end of the extruded monolithic carbonaceous material to an opposing second end of the extruded monolithic carbonaceous material. In some embodiments, the aerosol delivery device, particularly the heat source, can include a heat transfer component. In various embodiments, the heat transfer component can be proximate to the heat source; in some embodiments, the heat transfer component can be located within or within the heat source. Some examples of heat transfer components are described in U.S. Patent Application Publication No. 2019 / 0281891 to Hejazi et al., which is incorporated herein by reference in its entirety.

[0254] While in the illustrated embodiment, the grooves 216 of the heat source 204 are substantially equal in width and depth and substantially evenly distributed around the circumference of the heat source 204, other embodiments may include as few as two grooves, and still other embodiments may include as few as a single groove. Still other embodiments may not include any grooves at all. Additional embodiments may include multiple grooves that may be of unequal widths and / or depths and may be unequally spaced around the circumference of the heat source. In still other embodiments, the heat source may include grooves and / or slits extending longitudinally from a first end of the extruded monolithic carbonaceous material to its opposing second end. In some embodiments, the heat source may include a foamed carbon monolith formed by a foaming process of the type disclosed in U.S. Pat. No. 7,615,184 to Lobovsky, the entire contents of which are incorporated herein by reference. Thus, some embodiments may provide advantages related to reduced time spent igniting the heat source. In some other embodiments, the heat source may be co-extruded with a layer of insulation (not shown), thereby reducing manufacturing time and costs. Other embodiments of the fuel element include carbon fiber or other heat source embodiments of the type described in U.S. Pat. No. 4,922,901 to Brooks et al., such as those disclosed in U.S. Pat. App. Pub. No. 2009 / 0044818 to Takeuchi et al., each of which is incorporated herein by reference in its entirety.

[0255] Generally, a heat source is positioned sufficiently close to a substrate portion having one or more aerosol-forming materials such that an aerosol formed / volatilized by application of heat from the heat source to the aerosol-forming materials (as well as any flavoring substances, medications, and / or the like provided for delivery to the user) is delivered to the user through the mouthpiece. That is, when the heat source heats the substrate portion, an aerosol is formed, released, or generated in a physical form suitable for inhalation by the consumer. Note that the foregoing terms are intended to be interchangeable, such that references to release, releasing, releases, or released include form or generate, forming or generating, forms or generates, and formed or generated. Specifically, the inhalable substance is released in the form of a vapor or an aerosol or a mixture thereof.

[0256] 5 and 6 , outer packaging 202 can be provided to engage or otherwise join at least a portion of heat source 204 with at least a portion of substrate portion 210 and mouthpiece 214 together. In various embodiments, outer packaging 202 is designed to be held in the packaged position in any manner, including via adhesive, fasteners, or the like, allowing outer packaging 202 to remain in the packaged position. Alternatively, in some other aspects, outer packaging 202 can be designed to be removable, if desired. For example, outer packaging 202 can be removed from heat source 204, substrate portion 210, and / or mouthpiece 214 while the outer packaging 202 remains in the packaged position.

[0257] In some embodiments, in addition to the outer packaging material 202, the aerosol delivery device can also include a liner configured to surround at least a portion of the substrate portion 210 and the heat source 204. In other embodiments, the liner can surround only a portion of the length of the substrate portion 210, while in some embodiments, the liner can surround substantially the entire length of the substrate portion 210. In some embodiments, the outer packaging material 202 can include a liner. Thus, in some embodiments, the outer packaging material 202 and the liner can be separate materials provided together (e.g., bonded, fused, or otherwise joined together as a laminate). In other embodiments, the outer packaging material 202 and the liner can be the same material. In either case, the liner can be configured to thermally regulate heat generated by the ignited heat source 204 so that it is conducted radially outward from the liner. Thus, in some embodiments, the liner can be constructed of a metal foil material, an alloy material, a ceramic material, or other thermally conductive amorphous carbon-based and / or aluminum material, and in some embodiments, can include a laminate. In some embodiments, depending on the materials of the outer packaging 202 and / or the liner, a thin layer of insulating material may be provided radially outward from the liner. Thus, the liner, in some aspects, can advantageously provide a way to engage two or more separate components of the aerosol generating element 200 (e.g., the heat source 204, the substrate portion 210, and / or a portion of the mouthpiece 214), while also promoting heat transfer axially therealong but limiting heat conduction radially outward.

[0258] As shown in FIGS. 5-6 , the outer wrapping 202 (and, optionally, the liner and substrate portion 210) can also include one or more openings formed therethrough to allow air entry when drawing on the mouthpiece 214. In various embodiments, the size and number of these openings can vary based on the requirements of a particular design. In the embodiment shown, a plurality of openings 220 are located proximal to 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 wrapping 202 (and, in some embodiments, the liner) in the region of the mouthpiece 214 proximal to the filter 212. While other embodiments may vary, in the embodiment shown, the openings 220 include a plurality of openings substantially uniformly spaced around the outer surface of the aerosol generating element 200, and the openings 221 also include a plurality of openings substantially uniformly spaced around the outer surface of the aerosol generating element 200. In various embodiments, the multiple openings can be formed in various ways through the outer packaging material 202 (and, in some embodiments, the liner), but in the embodiment shown, the multiple openings 220 and the multiple separate cooling openings 221 are formed via laser drilling.

[0259] Referring again to Figures 5-6, the aerosol generating element 200 in the illustrated embodiment also includes an intermediate component 208 and at least one filter 212. Note that in various implementations, the intermediate component 208 or the filter 212, individually or together, may be considered the mouthpiece 214 of the aerosol generating element 200. While neither an intermediate component nor a filter need be included in various implementations, in the illustrated implementation, the intermediate component 208 comprises a substantially rigid member that is substantially inflexible along its longitudinal axis. In the illustrated implementation, the intermediate component 208 comprises a hollow tubular structure and is included to add structural integrity to the aerosol generating element 200 and to provide cooling for the generated aerosol. In some implementations, the intermediate component 208 can be used as a container to collect the aerosol. In various implementations, such components can be constructed from any of a variety of materials and can include one or more adhesives. Exemplary materials include, but are not limited to, paper, paper layers, paperboard, plastic, cardboard, and / or composite materials. In the illustrated implementation, the intermediate component 208 comprises a hollow cylindrical element constructed of paper or plastic material (e.g., ethyl vinyl acetate (EVA), or other polymeric materials such as polyethylene, polyester, silicone, etc., or ceramics (e.g., silicon carbide, alumina, etc.), or other acetate fibers), and the filter comprises a wrapped rod or cylindrical disk constructed of a gas permeable material (e.g., cellulose acetate or fibers such as paper or rayon, or polyester fibers).

[0260] As described, in some implementations, the mouthpiece 214 can include a filter 212 configured to receive aerosol therethrough in response to drawing on the mouthpiece 214. In various implementations, the filter 212 is provided as a circular disk, in some embodiments, radially and / or longitudinally disposed proximal to the second end of the intermediate component 208. In this manner, upon drawing on the mouthpiece 214, the filter 212 receives the aerosol flowing through the intermediate component 208 of the aerosol-generating element 200. In some implementations, the filter 212 can include separate segments. For example, some implementations can include a segment that provides filtering, a segment that provides resistance to draw, a hollow segment that provides space for cooling the aerosol, a segment that provides greater structural integrity, other filter segments, and any one or any combination of the above. In some implementations, the filter 212 can also or alternatively contain strands of tobacco-containing material, such as those described in U.S. Pat. No. 5,025,814 to Raker et al., which is incorporated herein by reference in its entirety.

[0261] In various implementations, the size and shape of intermediate component 208 and / or filter 212 may vary, for example, the length of intermediate component 208 may range from approximately 10 mm to approximately 30 mm (inclusive), the diameter of intermediate component 208 may range from approximately 3 mm to approximately 8 mm (inclusive), the length of filter 212 may range from approximately 10 mm to approximately 20 mm (inclusive), and the diameter of filter 212 may range from approximately 3 mm to approximately 8 mm (inclusive). In the implementation shown, intermediate component 208 has a length of approximately 20 mm and a diameter of approximately 4.8 mm (and in some implementations, approximately 7 mm), and filter 212 has a length of approximately 15 mm and a diameter of approximately 4.8 mm (or in some implementations, approximately 7 mm).

[0262] In various implementations, ignition of heat source 204 results in aerosolization of the aerosol-forming material associated with substrate portion 210. In certain embodiments, elements of substrate portion 210 do not undergo thermal decomposition (e.g., charring, scorching, or burning) to any significant extent, and the aerosolized components are entrained in air drawn through aerosol-generating component 200, including filter 212, and into the user's mouth. In various implementations, mouthpiece 214 (e.g., intermediate component 208 and / or filter 212) is designed to receive the generated aerosol therethrough in response to drawing on mouthpiece 214 by a user. In some implementations, mouthpiece 214 can be fixedly engaged to substrate portion 210. For example, adhesives, bonding, welding, etc., can be suitable for fixedly engaging mouthpiece 214 to substrate portion 210. In one example, mouthpiece 214 is ultrasonically welded and sealed to the end of substrate portion 210.

[0263] While the aerosol delivery device and / or aerosol generating element according to the present disclosure can take various embodiments as discussed in detail above, the use of the aerosol delivery device and / or aerosol generating element by a consumer falls within the same scope. The foregoing description of the use of the aerosol delivery device and / or aerosol generating element is applicable to the various embodiments described with minor modifications, which 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 and is provided to comply with all necessary requirements of the disclosure herein.

[0264] Many modifications and other embodiments of the present disclosure will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. It is to be understood, therefore, that the present disclosure is not limited to the specific embodiments disclosed herein, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. 1. An aerosol-generating substrate for use in an aerosol delivery device, comprising: Filler, one or more binders; one or more aerosol-forming materials, and A substrate comprising one or more capsules, each of the one or more capsules comprising a degradable outer shell or polymer matrix, the outer shell or polymer matrix encapsulating an inner payload.

2. 10. The substrate of claim 1, wherein one or more capsules comprises a stabilizer fixedly affixed to the outer shell or polymer matrix of the capsule.

3. The substrate of claim 1 , wherein the inner payload comprises an aerosol-forming material, an active ingredient, a flavoring substance, or a combination thereof.

4. 4. The substrate of claim 3, wherein the active ingredient is selected from the group consisting of nicotine components, botanical materials, stimulants, amino acids, vitamins, antioxidants, dietary supplements, cannabinoids, cannabimimetics, terpenes, pharmaceuticals, and combinations thereof.

5. 10. The substrate of claim 1, wherein the outer shell or polymer matrix of each of the one or more capsules is degradable upon exposure to heat.

6. 10. The substrate of claim 1, wherein the outer shell or polymer matrix of each of the one or more capsules is degradable upon exposure to moisture.

7. 10. The substrate of claim 1, wherein the outer shell or polymer matrix of each of the one or more capsules is degradable upon exposure to an enzyme.

8. The substrate of claim 1 , wherein the filler is selected from the group consisting of cellulosic materials, starches, sugars, or combinations thereof.

9. 10. The substrate of claim 1, wherein the filler comprises tobacco or non-tobacco botanical material in flake, granular, or particulate form.

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

11. 10. The substrate of claim 1, wherein the aerosol-forming material is present in an amount of about 20% by weight or greater, based on the total dry weight of the substrate.

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

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

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

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

16. 16. The substrate of claim 15, wherein the polyhydric alcohol is selected from the group consisting of glycerol, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, and combinations thereof.

17. The substrate of claim 1 , wherein the aerosol-forming material is glycerol.

18. The substrate of claim 1 , wherein the substrate has a form selected from the group consisting of particles, granules, pellets, flakes, strips, sheets, and films.

19. 10. The substrate of claim 1, wherein the outer shell or polymer matrix of one or more capsules comprises a polymer selected from the group consisting of gelatin, genipin-crosslinked gelatin, polyhydroxyalkanoate (PHA), polycaprolactone (PCL), pullulan, glucan, chitosan, ethylcellulose, and combinations thereof.

20. 10. The substrate of claim 1, wherein the outer shell or polymer matrix of one or more capsules has a thermal decomposition temperature of at least about 250°C.

21. 10. The substrate of claim 1, wherein the outer shell or polymer matrix of the one or more capsules has a thermal decomposition temperature of at least about 275°C.

22. 10. The substrate of claim 1, wherein the outer shell or polymer matrix of one or more capsules has a thermal decomposition temperature of at least about 300°C.

23. 10. The substrate of claim 1, wherein the outer shell or polymer matrix of one or more capsules has a thermal decomposition temperature of at least 325°C.

24. 10. The substrate of claim 1, wherein the thermal decomposition temperature of the outer shell or polymer matrix of the one or more capsules is from about 250°C to about 400°C.

25. 10. The substrate of claim 1, wherein the outer shell or polymer matrix of one or more capsules has a melting point of at least about 100°C.

26. 10. The substrate of claim 1, wherein the outer shell or polymer matrix of the one or more capsules has a melting point of at least about 125°C.

27. 10. The substrate of claim 1, wherein the outer shell or polymer matrix of the one or more capsules has a melting point of at least about 150°C.

28. 10. The substrate of claim 1, wherein the outer shell or polymer matrix of the one or more capsules has a melting point of at least about 200°C.

29. 10. The substrate of claim 1, wherein the melting point of the outer shell or polymer matrix of the one or more capsules is from about 100°C to about 350°C.

30. 30. An aerosol generating element for use with an aerosol delivery device, comprising a substrate according to any one of claims 1 to 29.

31. 31. The aerosol generating element of claim 30, further comprising a support, the substrate being affixed to the support.

32. 32. The aerosol generating element of claim 31 , wherein the support is planar.

33. 31. The aerosol generating element according to claim 30 . a heat source configured to heat the aerosol generating element to form an aerosol; and an aerosol pathway extending along a length from the aerosol generating element and configured to convey the aerosol to the mouth of the aerosol delivery device; 1. An aerosol delivery device comprising:

34. 34. The aerosol delivery device of claim 33, wherein the heat source comprises an electric heating element or a combustible ignition source.

35. 34. The aerosol delivery device of claim 33, wherein the heat source is a combustible ignition source comprising a carbon-based material.

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

37. 37. The aerosol delivery device of claim 36, further comprising a power source electronically connected to the heating element.

38. 37. The aerosol delivery device of claim 36, further comprising a controller configured to control the power delivered by the power source to the heating element.

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

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