Fibrous materials for aerosol delivery devices

Abstract

The present disclosure provides an aerosol-generating consumable for use in an aerosol delivery device, the consumable including a substrate including at least one aerosol-forming material and at least one outer covering material encasing at least a portion of the substrate, wherein at least one of the substrate and outer covering material includes a plurality of synthetic fibers, each fiber including a polymer matrix encapsulating an aerosolizable additive. An aerosol delivery device including the aerosol-generating consumable is also provided. Such a device utilizes an electrical heat source or a combustible ignition source to heat the aerosol-generating consumable and provides an inhalable substance in aerosol form.

Description

[Technical Field]

[0001] The present disclosure relates to aerosol generating elements, aerosol delivery devices and aerosol delivery systems that utilize electrical heat or a combustible ignition source to heat aerosol-forming materials to provide inhalable substances 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 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 burned and heat is transferred 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, U.S. Pat. No. 7,726,320 to Robinson et al.; U.S. Patent Application Publication No. 2013 / 0255702 to Griffith, Jr. et al.; and U.S. Patent Application Publication No. 2014 / 0096781 to Sears et al., each of which is incorporated herein by reference in its entirety, in the background art. [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] (Brief summary) The present disclosure relates to a substrate for use in an aerosol delivery device that provides an inhalable substance in aerosol form for human consumption by heating the substrate using an electrical heating or combustible ignition source. The present disclosure has the ability to retain more flavoring and / or aerosol-forming agents in the product without affecting the integrity of the substrate material. Furthermore, the present disclosure allows for greater stability of flavors, aerosol-forming materials, or other additives in the product.

[0007] In one or more embodiments, the present disclosure may provide an aerosol-generating consumable for use in an aerosol delivery device. For example, the aerosol-generating consumable may include a substrate including at least one aerosol-forming material and at least one envelope material encasing at least a portion of the substrate, wherein at least one of the substrate and envelope material includes a plurality of synthetic fibers (e.g., in the form of a nonwoven fibrous mat or web), each fiber including a polymer matrix encapsulating an aerosolizable additive. The synthetic fibers may be electrospun or otherwise prepared, for example, using other nonwoven melt-spinning techniques. The aerosolizable additive may include an aerosol-forming material, an active ingredient, a flavoring substance, or a combination thereof. Exemplary active ingredients include nicotine components, botanical materials, stimulants, amino acids, vitamins, antioxidants, nutraceuticals, cannabinoids, cannabimimetics, terpenes, pharmaceuticals, and combinations thereof.

[0008] The synthetic fibers can be degradable when exposed to heat. The synthetic fibers can be degradable when exposed to moisture. The synthetic fibers can be degradable when exposed to enzymes.

[0009] The aerosol-forming material can be present in an amount of about 3% by weight or more, based on the total dry weight of the substrate. The aerosol-forming material can be present in an amount of about 10% by weight or more, based on the total dry weight of the substrate. The aerosol-forming material can be present in an amount ranging from about 10% by weight to about 70% by weight. The aerosol-forming material can be present in an amount ranging from about 30% by weight to about 60% by weight. The aerosol-forming material can be 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. The aerosol-forming material can be a polyhydric alcohol. The polyhydric alcohol can be selected from the group consisting of glycerol, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, and combinations thereof. The aerosol-forming material can be glycerol.

[0010] The polymer matrix may comprise a polymer selected from the group consisting of gelatin, agarose, polycaprolactone, chitosan, glucan, pullulan, zein, ethyl cellulose, and combinations thereof. The thermal decomposition temperature of the polymer matrix may be at least about 250°C. The thermal decomposition temperature of the polymer matrix may be at least about 275°C. The thermal decomposition temperature of the polymer matrix may be at least about 300°C. The thermal decomposition temperature of the polymer matrix may be at least 325°C. The thermal decomposition temperature of the polymer matrix may be between about 250°C and about 400°C. The melting point of the polymer matrix may be at least about 100°C. The melting point of the polymer matrix may be at least about 125°C. The melting point of the polymer matrix may be at least about 150°C. The melting point of the polymer matrix may be at least about 200°C. The melting point of the polymer matrix may be between about 100°C and about 350°C.

[0011] The aerosol-generating consumable product can further include a support, the substrate being attached to the support. The support can be planar.

[0012] In one or more embodiments, the present disclosure can also provide an aerosol delivery device. For example, the aerosol delivery device can include the following: an aerosol generating consumable described herein, a heat source configured to heat a substrate to form an aerosol, and an aerosol pathway extending from the substrate and extending along a length configured to convey the aerosol to an orifice of the aerosol delivery device.

[0013] The heat source can include either an electrically driven heating element or a combustible ignition source. The heat source can be a combustible ignition source that can include a carbon-based material. The heat source can be an electrically driven heating element. The heat source can be a conductive heat source or an inductive heat source.

[0014] The aerosol delivery device can further include a power source electronically connected to the heating element. The aerosol delivery device can further include a controller configured to control power delivered by the power source to the heating element.

[0015] The present invention includes, without limitation, the following embodiments.

[0016] Embodiment 1: An aerosol-generating consumable for use in an aerosol delivery device, the consumable comprising: a substrate comprising at least one aerosol-forming material; and at least one outer covering material enclosing at least a portion of the substrate; wherein at least one of the substrate and the outer covering material comprises a plurality of synthetic fibers, each fiber comprising a polymer matrix encapsulating an aerosolizable additive.

[0017] Embodiment 2: The aerosol generating consumable of embodiment 1, wherein the synthetic fibers are electrospun.

[0018] Embodiment 3: The aerosol-generating consumable product of any one of embodiments 1-2, wherein the aerosolizable additive comprises an aerosol-forming material, an active ingredient, a flavoring substance, or a combination thereof.

[0019] Embodiment 4: The aerosol generating consumable of any one of embodiments 1 to 3, wherein the active ingredient is selected from the group consisting of nicotine components, botanical materials, stimulants, amino acids, vitamins, antioxidants, functional foods, cannabinoids, cannabimimetics, terpenes, pharmaceuticals, and combinations thereof.

[0020] Embodiment 5: The aerosol generating consumable according to any one of embodiments 1 to 4, wherein the synthetic fibers are degradable when exposed to heat.

[0021] Embodiment 6: The aerosol generating consumable according to any one of embodiments 1 to 5, wherein the synthetic fibers are degradable when exposed to moisture.

[0022] Embodiment 7: The aerosol generating consumable of any one of embodiments 1 to 6, wherein the synthetic fibers are degradable when exposed to an enzyme.

[0023] Embodiment 8: The aerosol-generating consumable product according to any one of embodiments 1 to 7, wherein the aerosol-forming material is present in an amount of about 3% by weight or more, based on the total weight of the substrate.

[0024] Embodiment 9: The aerosol-generating consumable product according to any one of embodiments 1 to 8, wherein the aerosol-forming material is present in an amount of about 10% by weight or more, based on the total weight of the substrate.

[0025] Embodiment 10: The aerosol-generating consumable product according to any one of embodiments 1 to 9, wherein the aerosol-forming material is present in an amount ranging from about 10% by weight to about 70% by weight, based on the total weight of the substrate.

[0026] Embodiment 11: The aerosol-generating consumable product according to any one of embodiments 1 to 10, wherein the aerosol-forming material is present in an amount ranging from about 30% by weight to about 60% by weight, based on the total weight of the substrate.

[0027] Embodiment 12: The aerosol generating consumable product of any one of embodiments 1 to 11, 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.

[0028] Embodiment 13: The aerosol-generating consumable product according to any one of embodiments 1 to 12, wherein the aerosol-forming material is a polyhydric alcohol.

[0029] Embodiment 14: The aerosol generating consumable product according to any one of embodiments 1 to 13, wherein the polyhydric alcohol is selected from the group consisting of glycerol, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, and combinations thereof.

[0030] Embodiment 15: The aerosol generating consumable according to any one of embodiments 1 to 14, wherein the aerosol-forming material is glycerol.

[0031] Embodiment 16: An aerosol generating consumable product described in any one of embodiments 1 to 15, wherein the polymer matrix comprises a polymer selected from the group consisting of gelatin, agarose, polycaprolactone, chitosan, glucan, pullulan, zein, ethylcellulose, and combinations thereof.

[0032] Embodiment 17: The aerosol-generating consumable product according to any one of embodiments 1 to 15, wherein the polymer matrix has a thermal decomposition temperature of at least about 250°C.

[0033] Embodiment 18: The aerosol-generating consumable product according to any one of embodiments 1 to 16, wherein the polymer matrix has a thermal decomposition temperature of at least about 275°C.

[0034] Embodiment 19: The aerosol-generating consumable product according to any one of embodiments 1 to 18, wherein the polymer matrix has a thermal decomposition temperature of at least about 300°C.

[0035] Embodiment 20: The aerosol-generating consumable product according to any one of embodiments 1 to 19, wherein the polymer matrix has a thermal decomposition temperature of at least about 325°C.

[0036] Embodiment 21: The aerosol generating consumable product according to any one of embodiments 1 to 20, wherein the thermal decomposition temperature of the polymer matrix is ​​between about 250°C and about 400°C.

[0037] Embodiment 22: The aerosol-generating consumable product according to any one of embodiments 1 to 21, wherein the polymer matrix has a melting point of at least about 100°C.

[0038] Embodiment 23: The aerosol-generating consumable product of any one of embodiments 1 to 22, wherein the polymer matrix has a melting point of at least about 125°C.

[0039] Embodiment 24: The aerosol-generating consumable product according to any one of embodiments 1 to 23, wherein the polymer matrix has a melting point of at least about 150°C.

[0040] Embodiment 25: The aerosol-generating consumable product according to any one of embodiments 1 to 24, wherein the polymer matrix has a melting point of at least about 200°C.

[0041] Embodiment 26: The aerosol generating consumable product according to any one of embodiments 1 to 25, wherein the melting point of the polymer matrix is ​​between about 100°C and about 350°C.

[0042] Embodiment 27: The aerosol generating consumable product according to any one of embodiments 1 to 26, further comprising a support, wherein the substrate is attached to the support.

[0043] Embodiment 28: The aerosol generating consumable product according to any one of embodiments 1 to 27, wherein the support is planar.

[0044] Embodiment 29: A consumable product for generating aerosols according to any one of embodiments 1 to 28. a heat source configured to heat the substrate to form an aerosol, and an aerosol pathway extending from the substrate and along a length configured to convey the aerosol to the mouth of the aerosol delivery device. 1. An aerosol delivery device comprising:

[0045] Embodiment 30: The aerosol delivery device of embodiment 29, wherein the heat source comprises either an electrically powered heating element or a combustible ignition source.

[0046] Embodiment 31: An aerosol delivery device described in any one of embodiments 29 to 30, wherein the heat source is a combustible ignition source comprising a carbon-based material.

[0047] Embodiment 32: An aerosol delivery device described in any one of embodiments 29 to 31, wherein the heat source is an electrically driven heating element.

[0048] Embodiment 33: An aerosol delivery device described in any one of embodiments 29 to 32, further comprising a power source electronically connected to the heating element.

[0049] Embodiment 34: An aerosol delivery device described in any one of embodiments 29 to 33, further comprising a controller configured to control the power delivered by the power source to the heating element.

[0050] Embodiment 35: An aerosol delivery device described in any one of embodiments 29 to 34, wherein the heat source is a conductive heat source or an inductive heat source.

[0051] 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 any combination of two, three, four, or more of the above-described embodiments, as well as combinations of any two, three, four, or more features or elements described in the present disclosure, regardless of whether such features or elements are explicitly combined in the description of a particular embodiment herein. The present disclosure is intended to be read as a whole, and whereby it should be considered that any separable features or elements of the present disclosure are intended to be combinable in any of its various aspects and embodiments, unless such context clearly dictates otherwise.

[0052] Having thus described aspects of the present disclosure in the foregoing general terms, reference is now made to the accompanying drawings, which are not necessarily drawn to scale and which are illustrative only and should not be construed as limiting the disclosure. [Brief explanation of the drawings]

[0053] [Figure 1] FIG. 1 is a close-up view of a synthetic fibrous material according to an exemplary embodiment of the present disclosure. [Figure 2] 1 illustrates an exemplary electrospinning process according to one embodiment of the present disclosure. [Figure 3] 1 is a schematic diagram of a cross-section of a layer of a substrate or packaging material having a layer of synthetic fibrous material applied thereto, according to one embodiment of the present disclosure; [Figure 4] 1 is a schematic diagram of a cross section of an aerosol generating element including a support and a substrate according to one embodiment of the present disclosure. FIG. [Figure 5] FIG. 1 is a perspective view of an aerosol delivery device including a controller and an aerosol generation element, the aerosol generation element and the controller being connected to each other, according to an exemplary embodiment of the present disclosure. [Figure 6]FIG. 6 is a perspective view of the aerosol delivery device of FIG. 5, with the aerosol generation element and the control device separated from each other, according to an exemplary embodiment of the present disclosure. [Figure 7] FIG. 1 is a schematic perspective view of an aerosol generation element according to an exemplary embodiment of the present disclosure. [Figure 8] 1 illustrates a perspective view of an aerosol generation element according to an exemplary embodiment of the present disclosure. [Figure 9] FIG. 9 is a perspective view of the aerosol generating element of FIG. 8 with the outer packaging removed, according to an exemplary embodiment of the present disclosure. [Figure 10] FIG. 2 is a schematic cross-sectional view of a substrate portion of an aerosol generating element according to an exemplary embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0054] 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.

[0055] As used in this specification and the claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0056] The term "about" is used throughout this specification to describe and explain small variations. For example, the term "about" can refer to less than or equal to ±10%, for example, less than or equal to ±5%, less than or equal to ±2%, less than or equal to ±1%, less than or equal to ±0.5%, less than or equal to ±0.2%, less than or equal to ±0.1%, or less than or equal to ±0.05%. All numerical values ​​herein are modified by the term "about", whether explicitly stated or not. Values ​​modified by the term "about" necessarily include the specific value. For example, "about 5.0" must include 5.0.

[0057] References to percentages are intended to mean weight percent unless otherwise indicated. References to "dry weight percent" or "dry weight basis" refer to weight based on dry ingredients (i.e., all ingredients excluding water). Weights presented on a dry weight basis refer to the entire slurry, material, etc., excluding water or other solvent, and may include ingredients that are themselves liquid at room temperature and pressure, such as glycerol or other aerosol-forming materials. Conversely, weight percentages presented on a wet weight basis refer to all ingredients, including water or other solvent.

[0058] The present disclosure generally relates to an aerosol-generating consumable for use in an aerosol delivery device, the consumable comprising a substrate comprising at least one aerosol-forming material and at least one casing material. At least one of the substrate and casing material comprises a plurality of synthetic fibers (e.g., electrospun fibers) comprising a polymer matrix encapsulating an aerosolizable additive, which can be any type of additive capable of forming an aerosol. The use of a synthetic fibrous material with an encapsulated additive can provide several benefits, including enhanced additive performance and improved additive stability in the consumable.

[0059] <Base material> As described hereinafter, exemplary embodiments of the present disclosure relate to substrates for use in aerosol delivery devices. The substrates can include various 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 some embodiments, one or more additional fillers can be used in combination with or in place of the tobacco or non-tobacco botanical materials. In some embodiments, synthetic fibers, e.g., electrospun fibers, are used as the only filler component of the substrate. Alternatively, synthetic fibers can be added as an additional layer to another filler component or intermixed with another filler component. Substrates according to the present disclosure can further include a binder and an aerosol-forming material. Each of the substrate components is further described herein below.

[0060] Filler The substrates disclosed herein optionally include a filler in addition to or in place of the tobacco material. Fillers can include, for example, non-tobacco botanical materials, cellulosic materials, wood fibers or pulp, starch, sugars, sugar alcohols, inorganic substances, inert materials, and combinations thereof. The amount of filler can vary. In some embodiments, the substrate includes up to about 70% dry weight filler, based on the total dry weight of the substrate. For example, in some embodiments, the substrate includes about 30% to about 70% filler by weight, based on the total dry weight of the substrate. More than one filler can be used. In such embodiments, it is understood that references to weight percent filler are intended to reflect the total amount of the combination of fillers present in the substrate.

[0061] 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 also function as a carrier, for example, a carrier for flavoring substances, in some embodiments. Microcrystalline cellulose has many uses, such as as a conditioner, anticaking agent, fat substitute, emulsifier, bulking agent, and bulking 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. Pulp is a lignocellulosic fibrous material prepared by chemically or mechanically separating cellulose fibers from wood, fiber crops, waste paper, or rags, while microcrystalline cellulose is distinguished as refined, partially depolymerized cellulose.

[0062] Cellulose is a naturally occurring polymer composed of glucose units linked by 1-4 β-glycosidic bonds. Linear cellulose is bundled together as microfibrils within plant cell walls. 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, β-cellulose is defined as a more degraded form of cellulose with fewer crystalline regions. γ-cellulose is further defined as a short-chain hemicellulose. Therefore, β-cellulose and γ-cellulose are typically removed from the inputs used to produce microcrystalline cellulose.

[0063] To produce microcrystalline cellulose, alpha cellulose can be first shredded and then immersed in a hot bath of mineral acid to dissolve the amorphous regions of the microfibrils while leaving the microcrystalline structure intact. The microcrystalline structure can then be subjected to hydrolysis to break down the long polymer chains until the degree of polymerization is reduced and the desired degree of stability is achieved. Chemicals and impurities can then be removed via washing with water followed by drying. The resulting microcrystalline cellulose can be embodied in raw form as a fine, white, crystallized powder. Methods for forming microcrystalline cellulose from plant materials are described, for example, in U.S. Patent No. 9,339,058 to Byrd, Jr. et al. and U.S. Patent No. 10,774,472 to Sebastian et al., both of which are incorporated herein by reference in their entireties. MCC materials are commercially available from manufacturers such as DuPont de Nemours, Inc., Asahi Kasei Corporation, Sigachi Industries Limited, Accent Microcell Pvt. Ltd., and DFE Pharma GmbH & Co. KG. The microcrystalline cellulose can be selected from the group consisting of AVICEL® grades PH-100, PH-102, PH-103, PH-105, PH-112, PH-113, PH-200, PH-300, PH-302, VIVACEL® grades 101, 102, 12, 20, and EMOCEL® grades 50M and 90M, and the like, and mixtures thereof.

[0064] Microcrystalline cellulose is usually used in particulate form, and particle size can vary.In some embodiments, microcrystalline cellulose material is in the form of very fine particulate, 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 by using a particle size analyzer.

[0065] In some embodiments, the microcrystalline cellulose material has a relatively low bulk density compared to other types of cellulose materials, which is advantageous when a material with a higher packing value is desired. Exemplary bulk density ranges for the 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 known mass of powder.

[0066] In some embodiments, compared to other cellulosic materials, microcrystalline cellulose can advantageously provide one or more of improved texture, anti-caking, and anti-stick properties to substrates comprising microcrystalline cellulose.

[0067] 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, from about 25%, about 30%, about 35%, about 40%, or about 45% microcrystalline cellulose, up to about 50%, about 55%, or about 60% microcrystalline cellulose.

[0068] 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.

[0069] In some embodiments, the cellulosic material is a cellulosic pulp or regenerated cellulose containing at least about 90% by weight cellulose, e.g., about 90%, about 95%, about 99%, or even up to 100% by weight cellulose. "Regenerated cellulose" refers to natural cellulose that has been regenerated by conversion to a soluble or dissolvable cellulosic derivative and subsequently formed into fibers, typically via polymer spinning or film polymer casting, precipitation, or extrusion.

[0070] 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. By way of non-limiting example, a suitable nanocellulose material may be a fibrous material prepared from any suitable cellulose-containing material, such as grasses (e.g., bamboo), cotton, tobacco, algae, and other plant-based materials, where the fibers are further refined to produce nanofibrillated cellulose fibers.

[0071] 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.

[0072] In some embodiments, the substrate is substantially or completely free of wood fiber or wood pulp. By "substantially free" of wood fiber or pulp, it is meant that no wood fiber or pulp has been intentionally added, beyond trace amounts that may be naturally present, for example, in botanicals or other plant materials. For example, some embodiments can 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. In some embodiments, the filler comprises a combination of microcrystalline cellulose and wood pulp.

[0073] 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 material as "non-tobacco" is intended to exclude tobacco materials (i.e., not including any Nicotiana species). As used in this disclosure, botanical material can 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, functional foods, "phytocompounds" or "functional foods."

[0074] 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, cam (Myrcaria dubia), hemp / cannabis, caraway seeds, catnip, catuaba, cayenne, cayenne pepper, chaga, chamomile, cherries, chervil, chocolate, cinnamon (Cinnamomum cassia), citrongrass (Cymbopogon citratus), clary sage, cloves, coconut (Cocos nucifera), coffee, comfrey leaves and root, coriander seeds, cranberries, dandelions, echinacea, elderberries, elderberry, endorphins (Anethum gravellens) graveolens), evening primrose, eucalyptus, fennel, feverfew, garlic, ginger (Zingiber 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, mentha piperita, peppermint (Mentha piperita) piperita), potato peelings, 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.

[0075] In some embodiments, the substrate comprises a plant-derived non-tobacco material, including, but not limited to, eucalyptus, rooibos, star anise, fennel, hemp, flax, sisal, rice straw, esparto, and combinations thereof.

[0076] 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.

[0077] Starch and sugar In some embodiments, the filler comprises starch, including native and modified starches. Certain starch materials may also be included in the substrate as binders or other functional additives. "Starch," as used herein, can refer to pure starch from any source, modified starch, or starch derivatives. Starch is 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 acorns, arrowroot, arracacha, bananas, barley, legumes (e.g., broad beans, lentils, mung beans, beans, chickpeas), breadfruit, buckwheat, canna, chestnut, taro, dogtooth violet, arrowroot, malanga, millet, oats, 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), cross-linking, 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 phosphated starch, glycerol cross-linked starch, phosphate cross-linked starch esterified with sodium trimetaphosphate, phosphate monoesterified phosphate cross-linked starch, acetylated phosphate cross-linked starch, starch acetate esterified with acetic anhydride, starch acetate esterified with vinyl acetate, acetylated adipate cross-linked starch, acetylated glycerol cross-linked starch, hydroxypropyl starch, hydroxypropylated glycerol cross-linked starch, and sodium starch octenylsuccinate.

[0078] 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 or completely free of rice starch and rice flour. "Substantially free" of rice starch and rice flour means that no rice starch or rice 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.

[0079] In some embodiments, the filler comprises a sugar. Suitable sugars include, but are not limited to, glucose, dextrose, fructose, maltose, and lactose.

[0080] 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.

[0081] Inorganic and inert materials 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, such as cellulose fibers in a tobacco cast sheet) or structured (e.g., wire mesh) materials.

[0082] Binder The substrates disclosed herein can include a binder. The binder (or combination of binders) can be utilized in an amount sufficient to provide the substrate with the desired physical characteristics and physical integrity. The amount of binder utilized can vary. In some embodiments, the binder is present in an amount of from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, or 35 wt%, to about 40 wt%, 45 wt%, 50 wt%, 55 wt%, or 60 wt%, based on the dry weight of the substrate. Some embodiments are characterized by a binder content of at least about 1 wt%, e.g., from about 1 to about 30 wt%, or from about 1 to about 20 wt%, or from about 5 to about 15 wt%, based on the total wet weight of the substrate. In some embodiments, the binder is present in an amount of from about 5 to about 9 wt%, or from about 7 to about 11 wt%, or from about 6 to about 12 wt%, based on the total dry weight of the substrate.

[0083] Typical binders can 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 can be utilized.

[0084] In some embodiments, the binder may comprise alginate, pectin, agar, agarose, gelatin, carrageenan, gum, cellulose derivatives, pullulan, starch or derivatives thereof, silica or silicone compounds, clay, polymers, or combinations thereof.

[0085] In some embodiments, the binder can include 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, on a dry weight basis, about 1 to about 15 wt. % alginate, for example, about 5 to about 10 wt. % alginate, based on the total dry weight of the substrate.

[0086] In some embodiments, the binder can comprise pectin. In some embodiments, the binder can comprise alginate and / or pectin, which can be combined with a stiffening agent (e.g., a calcium source) during substrate formation. In some embodiments, the substrate can comprise calcium-crosslinked alginate, calcium- or acid-crosslinked pectin, or both.

[0087] In some embodiments, the binder can comprise 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.

[0088] In some embodiments, the binder may include silica, fumed silica, sodium silicate, polydimethylsiloxane, kaolin, polyvinyl alcohol, or a combination thereof.

[0089] In some embodiments, the binder may comprise 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 (available from Aqualon Co.); hydroxypropyl methyl cellulose, such as Methocel K4MS (available from DuPont); hydroxyethyl cellulose, such as Natrosol 250MRCS (available from Aqualon Co.); methyl cellulose, such as Methocel A4M, K4M, and E15 (available from DuPont); and sodium carboxymethyl cellulose, such as CMC 7HF, CMC 7LF, and CMC 7H4F (available from Aqualon Co.). In some embodiments, the binder is one or more cellulose ethers (e.g., a single cellulose ether or 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, hydroxypropylcellulose, hydroxypropylmethylcellulose, hydroxyethylcellulose, carboxymethylcellulose, and combinations thereof. In some embodiments, the binder is carboxymethylcellulose. In some embodiments, the binder is hydroxypropylmethylcellulose.

[0090] In some embodiments, the substrate can include carboxymethylcellulose 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.

[0091] <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 may 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.

[0092] The amount of aerosol-forming material incorporated (e.g., carried or impregnated) into the substrate can vary and is generally such that the aerosol-generating element containing the substrate provides acceptable sensory 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 in the aerosol-generating element (e.g., impregnated substrate) can depend on factors such as the number of puffs desired per aerosol-generating element.

[0093] In some embodiments, the substrate, when loaded, comprises at least about 0.1 wt.%, at least about 0.5 wt.%, at least about 1 wt.%, at least about 5 wt.%, at least about 10 wt.%, at least about 15 wt.%, at least about 20 wt.%, at least about 25 wt.%, at least about 30 wt.%, at least about 35 wt.%, at least about 40 wt.%, at least about 45 wt.%, at least about 50 wt.%, at least about 55 wt.%, at least about 60 wt.%, at least about 65 wt.%, at least about 70 wt.%, at least about 75 wt.%, or at least about 80 wt.% of the aerosol-forming material, based on the total weight of the impregnated substrate, on a dry weight basis. 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 weight of the impregnated substrate. In some embodiments, the substrate comprises the aerosol-forming material in an amount of about 10% to about 70%, about 40% to about 60%, about 30% to about 60%, or about 25% to about 45% by weight, based on the total weight of the substrate.

[0094] 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).

[0095] 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.

[0096] 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.

[0097] 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.

[0098] 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).

[0099] 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.

[0100] 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.

[0101] 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.

[0102] 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.

[0103] 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.

[0104] 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.

[0105] 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.

[0106] <Synthetic fiber> Synthetic fibers, also referred to herein as synthetic fibrous materials, include fibers containing an aerosolizable additive encapsulated within a polymer matrix. In this context, reference to "synthetic" merely indicates that the fiber is formed by a synthetic process, as opposed to a naturally occurring fiber. In some embodiments, the additive is present only in the synthetic fiber. In some embodiments, the additive is present in both the synthetic fiber and elsewhere in the substrate or other portions of the consumable.

[0107] In one embodiment, the synthetic fibrous material has a relatively homogeneous structure and includes a matrix of polymeric material with an encapsulated additive dispersed within the polymer matrix. For example, some embodiments of the present invention include a plurality of electrospun fibers, the fibers including a polymer matrix. The polymer matrix includes an encapsulated aerosolizable additive throughout, typically adapted to enhance one or more sensory properties of the substrate, such as taste, moistness, cooling / warming sensations, and / or fragrance, or to add additional sensory qualities to the consumable, such as antioxidants or immune system boosting. The polymer matrix acts as a barrier between the additive and the substrate or other portions of the consumable. This barrier is typically intended to be temporary, meaning that it is designed to cease serving as a barrier and thereby release the aerosolizable additive under certain conditions of use of the product.

[0108] In many embodiments, the aerosolizable additive within the polymer matrix is ​​released when the fibrous material undergoes some type of physical disruption, breakage, or other loss of physical integrity (e.g., via disintegration, softening, crushing, application of pressure, etc.), thereby changing the sensory or organoleptic properties of the substrate or consumable during product use. Thus, for example, the fibrous material can be wrapped around a substrate, and during use, contact of the fibrous material with moisture can cause the polymer matrix to soften, lose its physical integrity, and release the additive. Alternatively, the polymer matrix can soften, lose its physical integrity, and release the additive upon contact with an enzyme. In another example, the polymer matrix can soften, lose its physical integrity, and release the additive upon exposure to elevated temperatures (e.g., 60-200°C). Such activation or release of the additive can change or enhance the flavor or other sensory properties of the substrate or consumable, extend the period during which the consumable can be enjoyed by the user, or provide other organoleptic benefits.

[0109] The polymer matrix can encapsulate any type of additive useful for use in aerosol-forming substrates for aerosol delivery devices, such as the aerosol-forming materials, active ingredients, or flavoring substances described herein.

[0110] Exemplary synthetic fiber materials can include polymer matrices containing materials such as gelatin, agarose, polycaprolactone, chitosan, glucan, pullulan, zein, ethylcellulose, and combinations thereof. The encapsulated additive can be, for example, an aqueous or non-aqueous liquid (e.g., a solution or dispersion of at least one flavoring component in water or an organic liquid, such as alcohol or oil; or a mixture with a water-miscible liquid, such as alcohol or glycerin). The synthetic fiber material can be attached to or associated with a substrate or other part of a consumable product, and during use of the product, physical disruption or degradation of the fibrous material can allow the polymer matrix to release the additive contained therein, thereby providing adequate wetting of the components of the substrate formulation and other organoleptic benefits, such as enhanced taste.

[0111] The synthetic fibers disclosed herein can be uniform in size, weight, and shape, or can vary in size, weight, and shape, depending on the desired properties of the consumable material. The fibers can be monocomponent or bicomponent, e.g., fibers having a core / sheath structure in which different polymers are used in the core and sheath, respectively. In this manner, the core and sheath can exhibit different release characteristics in relation to the aerosolizable additive. Exemplary synthetic fibers have diameters ranging from about 50 nm to about 2 microns, e.g., from about 100 nm to about 1 micron.

[0112] The total weight of the synthetic fibrous material in the consumable may vary, but is typically greater than about 10 mg, often greater than about 20 mg, and can be greater than about 30 mg. The total weight of the fibrous material is typically less than about 200 mg, often less than about 100 mg, and can be less than about 50 mg.

[0113] The synthetic fibers of the present disclosure can be formed using a variety of fiber-forming techniques, including electrospinning. Electrospinning utilizes the interplay between electrical forces and surface tension to create fibers by applying a strong electric field between droplets of charged polymer solution and a collection plate. Typically, droplets of charged polymer solution are expelled through a spinneret to form substantially continuous, ultrathin fibers, which can be collected on a collection plate in the form of a fibrous nonwoven mat. While the methods disclosed herein describe the formation of a "mat," it is understood that collection surfaces of different shapes can also be used (e.g., fibers can be collected on a rotating mandrel to form a tube-like structure).

[0114] A typical electrospinning apparatus is shown in Figure 2, which illustrates the deposition of nanofibers from an electrically charged syringe pump onto a collection plate. This electrospinning setup essentially consists of a metal needle attached to a syringe filled with a polymer solution, a grounded collector, and a high-voltage power supply connected between the needle and the collector, which provides positive and negative charges, respectively. The polymer solution typically contains the polymer or polymer blend to be electrospun, one or more solvents, and additives to be encapsulated within the fibrous material. The solvent(s) can be, for example, acetic acid, ethanol, water, tetrahydrofuran, dimethylformamide, and / or dichloromethane. The concentration of the polymer solution can vary; in some embodiments, the polymer solution can contain about 5% to about 25% by weight of polymer, based on the weight of the solution. The amount of additive in the polymer solution can vary, but typically ranges from 5% to about 20% by weight, based on the weight of the polymer solution.

[0115] The polymer solution feed rate can be controlled, for example, by metering with a syringe pump. During electrospinning, the polymer solution is delivered to the needle at a constant rate, and a pendant droplet of solution appears at the needle tip. By increasing the voltage applied to the needle, the charged droplet deforms into a conical shape known as a "Taylor cone." As the strength of the applied voltage increases to a point where the electrostatic force overcomes the surface tension of the solution, a fine jet of solution erupts from the droplet and moves toward a collector. The jet initially follows a linear path, but then "bending instability" occurs due to the repulsion of charges within the jet. During this stage, the jet is stretched, the solvent evaporates, and fine fibers are deposited on the collector. The fine fibers can be deposited in an aligned fashion, but more commonly they are deposited in a random alignment (e.g., forming a random fiber web).

[0116] Electrospinning can provide fibers having a variety of average diameters, including micrometer and nanometer diameters. For example, the electrospun fibers described herein are generally intended to include fibers having an average outer diameter between about 20 nm and about 5 μm, typically between about 500 nm and about 2 μm. The average outer diameter can vary, in some embodiments, depending on the particular type and geometry of the fiber being produced. The average porosity of mats produced by electrospinning can vary, but is typically greater than about 80%.

[0117] In various embodiments of the present disclosure, electrospun fibers can have a range of morphologies, such as single component fibers, porous fibers, and core-sheath fibers. The different morphologies and structures of electrospun fibers can have a significant impact on their potential for additive release and material applications.

[0118] There are several intrinsic and extrinsic factors in electrospinning that depend on the specific equipment and polymer system. Intrinsic factors include, but are not limited to, solution parameters such as polymer concentration, solvent system, viscosity, and conductivity. For example, the polymer concentration and / or viscosity of the solution must be high enough to ensure a sufficient amount of chain entanglement and allow the formation of substantially continuous fibers rather than small droplets. Extrinsic factors include, but are not limited to, solution feed rate, electric field, and environmental parameters such as temperature and humidity. For example, temperature and humidity significantly affect fiber formation because they alter solvent evaporation, which can lead to morphological changes and disrupt fiber formation. Volumetric flow rate determines how large the pendant droplets become and can alter Taylor cone formation. Electric field strength is critical in overcoming the inherent surface tension of the polymer and is the force required to generate a stable Taylor cone. Figure 1 illustrates a close-up view of an exemplary synthetic fiber material in the form of a web 10 comprising a plurality of fibers 20 prepared by electrospinning according to one embodiment of the present disclosure.

[0119] Regardless of the fiber formation method utilized, the polymer matrix, solvents, and additives used to form the synthetic fibrous materials of the present disclosure can vary and depend in part on the desired release characteristics of the synthetic fibrous material (e.g., moisture interaction, enzyme interaction, or heat-based release). Classes of materials commonly used as polymer matrix materials include proteins, polysaccharides, starches, waxes, fats, natural and synthetic polymers, and resins. Exemplary materials for use in the encapsulation process used to form the fibrous material 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. Additional examples include agarose, polycaprolactone, chitosan, glucan, pullulan, zein, polyhydroxyalkanoates (PHAs) and poly(N-isopropylacrylamide (PNIPAAm)), and cyclodextrins.

[0120] In some embodiments, when the synthetic fibers are intended to be degraded via heating, the polymer matrix material can include, for example, gelatin, agarose, polycaprolactone, chitosan, and glucan, which have low melting and decomposition temperatures, and / or pullulan, zein, and ethylcellulose, which have high melting and decomposition temperatures. It can be advantageous for the polymer 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 the consumable containing the encapsulated ingredient is ready for use). It can also be advantageous for the thermal decomposition temperature of the polymer to exceed the maximum operating temperature of the device (to prevent the release of thermal decomposition products). For example, in some embodiments, the polymer 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 some embodiments, the 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).

[0121] <Active ingredient> As used herein, "active ingredient" refers to one or more additives or substances belonging to any of the following categories: APIs (active pharmaceutical agents), food additives, natural medicines, and naturally occurring substances that can have an effect on humans. Exemplary active ingredients include any ingredient known to affect one or more biological functions in the body, such as ingredients that provide pharmacological activity or other direct action in the diagnosis, cure, mitigation, treatment, or prevention of disease, or ingredients that affect the structure or any function of the human body (e.g., 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, functional food, "botanical compound," or "functional food." These types of additives are sometimes defined in the art to include substances that provide one or more beneficial biological effects (e.g., health promotion, disease prevention, or other pharmacological effects) but are commonly available from naturally occurring sources (e.g., botanical materials) that are not classified or regulated as drugs.

[0122] 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, prophylactic, or diagnostic activity. Non-limiting examples of active ingredients include those in the categories of botanical ingredients, stimulants (e.g., caffeine and guarana), amino acids (e.g., taurine, theanine, phenylalanine, tyrosine, and tryptophan), and / or pharmaceutical, nutraceutical, and medicinal ingredients (e.g., vitamins, e.g., B6, B12, and C, and / or cannabinoids, e.g., tetrahydrocannabinol (THC) and cannabidiol (CBD)), antioxidants, and nicotine ingredients. The specific choice of active ingredient will depend on the desired flavor, texture, and desired characteristics of the particular product.

[0123] The specific percentage of active ingredient(s) present will vary depending on the desired characteristics of the particular product. Typically, the active ingredient(s) or combination(s) thereof will be present at a total concentration of at least about 0.001% by weight of the substrate and / or synthetic fibrous material, e.g., in the range of about 0.001% to about 20%. In some embodiments, the active ingredient(s) or combination(s) 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 substrate and / or synthetic fibrous material. 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 It is present in a concentration of from 0.07%, about 0.08%, about 0.09%, about 0.1%, about 0.2%, about 0.3%, about 0.4%, about 0.5%, about 0.6%, about 0.7%, about 0.8%, or about 0.9% by weight 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.

[0124] botanical In some embodiments, the active ingredient comprises one or more non-tobacco botanicals. As used herein, the term "botanical ingredient" or "botanical" refers to any plant or fungal-derived material, including plant material in its natural form (e.g., leaves, bark, fiber, stems, roots, seeds, flowers, fruits, pollen, husks, shells, etc.) and plant material derived from natural plant material, such as an extract or isolate from 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).

[0125] 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). Calling a botanical material "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, functional foods, "phytocompounds," or "functional foods."

[0126] 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, bee balm, beetroot, bergamot, black pepper, black tea, blueberry, borage seed oil, lily of the valley, cacao, calamus root, cardamom, black currant, catnip, catuaba, cayenne pepper, Centella asiatica (Centella asiatica) asiatica, chaga, bupleurum, chamomile, cherry blossom, chervil, chives, chlorophyll, dark chocolate, cilantro, cinnamon, citrus fruits, cloves, cocoa, coffee, comfrey leaves and root, 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, erinaceus, lutein, maca, mace, marjoram, matcha green tea, mulberry, Nardostachys chinensis, marjoram, milk thistle, mint, myrtle, nutmeg, olive, oolong tea, orange, oregano, papaya, paprika, morning glory, peppermint, peppermint, pimento, potato peel, primrose, quercetin, red clover, resveratrol, Rhizoma gastrodiagastrodiae, Rhodiola, rooibos, rooibos (red or green), rose essential oil, rosehips, rosemary, saffron, sage, clary sage, sandalwood, savory, saw palmetto, Sceletium tortuosum, schisandra, Silvum marianeum, skullcap, spearmint, spikenard, spirulina, slippery elm bark, high-tannin sorghum bran, high-tannin sorghum grain, St. John's wort, star anise, sumac bran, tarragon, terpenes, thyme, tisane, turmeric, Turnera aphrodisiaca, bearberry, valerian, vanilla, Viola odorata odorata), white mulberry, wild yam root, wintergreen, Withania somnifera, yacon root, yellow dock, yerba mate, and yerba santa.

[0127] 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.

[0128] When present, the botanical active ingredient is typically at a concentration of about 0.01% w / w to about 10% by weight, for example, from about 0.01% w / w, about 0.05%, about 0.1% or about 0.5%, up to about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9% or about 10%, about 11%, about 12%, about 13%, about 14% or about 15% by weight, based on the total weight of the substrate and / or synthetic fibrous material composition.

[0129] 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 nicotine may vary and may be natural or synthetic. Most preferably, the nicotine is naturally derived and obtained as an extract from Nicotiana species (e.g., tobacco). The nicotine may 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 primarily or predominantly composed 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.

[0130] 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 and / or synthetic fibrous material may include a nicotine component. In various embodiments, the substrate and / or synthetic fibrous material may be free of a nicotine component. In some embodiments, the substrate and / or synthetic fibrous material may include a non-tobacco-derived nicotine component.

[0131] 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 and / or synthetic fibrous material, 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 and / or fibrous material. In some embodiments, the nicotine component is present at a concentration of about 0.1% w / w to about 3% by weight, calculated as the free base, based on the total weight of the substrate or synthetic fibrous material, e.g., about 0.1% w / w to about 2.5% by weight, about 0.1% to about 2.0% by weight, about 0.1% to about 1.5% by weight, or about 0.1% to about 1% by weight. These ranges may also apply to other active ingredients described herein.

[0132] In some embodiments, the substrates and / or synthetic fibrous materials of the present disclosure can be characterized as being completely free or substantially free of nicotine components. By "substantially free of nicotine components," it is meant that no nicotine has been intentionally added beyond the trace amounts that may be naturally present in, for example, botanical materials. For example, some 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.

[0133] 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), altering the release of neurotransmitters in the brain. Cannabinoids are cyclic molecules that exhibit certain properties, such as the ability to easily cross the blood-brain barrier. Cannabinoids may 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).

[0134] 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).

[0135] In some embodiments, the cannabinoid (e.g., CBD) is added to the substrate and / or synthetic fibrous material 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.

[0136] In some embodiments, the cannabinoid is a highly pure isolate of CBD, and the amount of any other cannabinoids therein is about 1% or less by weight of the total substrate, for example, about 0.5% or less by weight of the substrate and / or synthetic fibrous material, for example, about 0.1% or less by weight of the substrate and / or synthetic fibrous material, for example, about 0.01% or less by weight of the substrate and / or synthetic fibrous material.

[0137] The selection of cannabinoids and their specific percentages that may be present within the disclosed fibrous materials and / or substrates will depend on the desired characteristics of the substrate or consumable.

[0138] In some embodiments, the cannabinoid (e.g., CBD) is present in the substrate and / or synthetic fibrous material at a concentration of at least about 0.001% by weight of the substrate and / or synthetic fibrous material, for example, from about 0.001% to about 2% by weight of the substrate and / or synthetic fibrous material. In some embodiments, the cannabinoid (e.g., CBD) is present in the substrate and / or synthetic fibrous material at a concentration of from about 0.1% to about 1.5% by weight, based on the total weight of the substrate and / or synthetic fibrous material. In some embodiments, the cannabinoid (e.g., CBD) is present in the substrate and / or synthetic fibrous material at a concentration of from about 0.4% to about 1.5% by weight, based on the total weight of the substrate and / or synthetic fibrous material.

[0139] Instead of or in addition to cannabinoids, the active ingredient can include cannabimimetics, 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.

[0140] 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.

[0141] 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.

[0142] 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.

[0143] The terpenes and / or cannabinoids may be present in the substrate and / or synthetic fibrous material as an active ingredient, as an aerosol-forming material, or as a flavoring ingredient. The amount of terpenes and / or cannabinoids present may vary accordingly based on their intended purpose.

[0144] <Flavor substances> In some embodiments, the substrate and / or synthetic fibrous material comprises 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 and / or synthetic fibrous 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, kalvi, cascarilla, cassia, black currant, celery, chamomile, cherry, cherry blossom, chives, cilantro, cinnamon, citrus fruits, clementine, clove, cocoa, coffee, cognac, coriander, cranberry, cucumber, cumin, curcuma, damiento, dragon fruit, drambuie, durian, elderberry, eucalyptus, eugenol, fennel, fenugreek, flax, geranium, gin, ginger, ginkgo biloba, grape, guayusa, hazel, cannabis, hibiscus, honeybush, honey essence, hydrangea, Indian spices, jasmine, Juniper, khat, lavender, laurel, lemon, lemongrass, lemon balm, lemon oil, lemon peel, licorice, lime, limonene, mace, oak, mango, maple, marjoram, matcha, yerba mate, menthol, mint, myrtle, mulberry, nasturtium, nutmeg, olive, orange blossom, orange oil, orange peel, oregano, papaya, paprika, peach, peppermint, bell pepper, pimento, pine, 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.

[0145] Flavoring substances may further include flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, and trigeminal sensate agents. As used herein, "trigeminal sensate agent" refers to a flavoring agent that acts on the trigeminal nerve to produce sensations including heating, cooling, tingling, etc. Non-limiting examples of trigeminal sensate flavoring agents include capsaicin, citric acid, menthol, szechuan peony, erythritol, and cucurbit.

[0146] Further non-limiting examples include flavorings and flavor packages of the type and nature customarily used for flavoring 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, for example, terpenes, terpenoids, aldehydes, ketones, esters, and other ingredients. 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 potential enhancing components are described in U.S. Patent Application Publication No. 15 / 707,461 to Phillips et al., which is incorporated herein by reference in its entirety.

[0147] 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 substrate and / or synthetic fibrous material. For example, the flavor substance may be present in an amount from about 0.1%, about 0.5%, about 1%, or about 5% by weight of the total substrate and / or synthetic fibrous material, up to about 10%, about 20%, or about 30% by weight.

[0148] <Water> The moisture (e.g., water) content of the substrate and / or synthetic fibrous material can vary. For example, in some embodiments, the substrate or synthetic fibrous material contains from about 0% to about 30% water by weight. In some embodiments, the substrate or synthetic fibrous material is dried during preparation to remove at least a portion of the water present. In some embodiments, after drying, the substrate and / or synthetic fibrous material contains from about 3 to about 21% water, based on the total weight of the substrate and / or synthetic fibrous material. In some embodiments, after drying, the substrate and / or synthetic fibrous material contains from about 8 to about 10% or from about 12 to about 18% water, based on the total weight of the substrate and / or synthetic fibrous material. In some embodiments, after drying, the substrate and / or synthetic fibrous material contains from about 15 to about 21% water, based on the total weight of the substrate and / or synthetic fibrous material.

[0149] <Coloring agent> In some embodiments, the substrate and / or synthetic fibrous material comprises a colorant. The addition of a colorant can change the visual appearance of the substrate and / or synthetic fibrous material. The presence of a colorant can enhance the visual appearance of the substrate and / or synthetic fibrous material. By adding a colorant to the substrate and / or synthetic fibrous material, the substrate and / or synthetic fibrous material can be color-matched to other components of the aerosol-generating element or other components of an article that includes the substrate and / or synthetic fibrous material.

[0150] Various colorants can be used depending on the desired color of the substrate and / or synthetic fibrous material. The color of the substrate and / or synthetic fibrous material 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, can be used. In some embodiments, the colorant is caramel, which can impart a brown appearance to the substrate and / or fibrous material. In such embodiments, the color of the substrate and / or synthetic fibrous material can be similar to the color of other components (e.g., tobacco material) in the aerosol-generating element that includes the substrate and / or synthetic fibrous material. In some embodiments, the addition of the colorant to the substrate and / or synthetic fibrous material makes it visually indistinguishable from the other components. The colorant can be incorporated into the substrate and / or synthetic fibrous material during its formation (e.g., when forming a slurry including the materials that form the substrate), or the colorant can be applied to the substrate and / or synthetic fibrous material after its formation (e.g., by spraying it onto the substrate and / or synthetic fibrous material).

[0151] <Tobacco materials> In some embodiments, the substrate, the aerosol-generating element comprising the substrate, the synthetic fibrous material, 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. Patent Nos. 4,660,577 to Sensabaugh, Jr. et al.; 5,387,416 to White et al.; 7,025,066 to Lawson et al.; 7,798,153 to Lawrence, Jr.; and 8,186,360 to Marshall et al., each of which is incorporated herein by reference. 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.

[0152] 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 U.S. Patent Nos. 5,539,093 to Fitzmaurice et al.; 5,668,295 to Wahab et al.; 5,705,624 to Fitzmaurice et al.; 5,844,119 to Weigl; 6,730,832 to Dominguez et al.; 7,173,170 to Liu et al.; 7,208,659 to Colliver et al. and 7,230,160 to Benning et al.; U.S. Patent Application Publication No. 2006 / 0236434 to Conkling et al.; and PCT Publication No. WO2008 / 103935 to Nielsen et al. See also the tobacco types described in U.S. Patents 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.

[0153] 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 some 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.

[0154] Various parts or portions of a plant of a Nicotiana species may be included within the substrate and / or synthetic fibrous material 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 and / or synthetic fibrous material disclosed herein can include processed tobacco parts or pieces, cured and aged tobacco in essentially natural lamina and / or stem form. In some embodiments, the tobacco material comprises a solid tobacco material selected from the group consisting of lamina and stem. The tobacco used for the substrate and / or synthetic fibrous material most preferably comprises tobacco lamina or a mixture of tobacco lamina and stem, 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. Patents 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. Additionally, the substrate and / or fibrous material can incorporate fermented tobacco. See also the types of tobacco processing techniques described in PCT WO 2005 / 063060 to Atchley et al., which is incorporated by reference herein.

[0155] Tobacco materials are typically used in a form that can be described as particulate, such as shredded, ground, granulated, pulp, or powder. 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.

[0156] 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 subjected to rolling). 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.

[0157] Harvested plants of Nicotiana species are typically subjected to a curing process. The tobacco material incorporated into the substrate and / or synthetic fibrous material disclosed herein is generally a material that has been appropriately cured and / or aged. 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 U.S. Patent No. 6,895,974 to Peele, which are incorporated herein by reference. Representative techniques and conditions for air-curing tobacco are described in U.S. Patent No. 7,650,892 to Groves et al.; Roton et al., Beitrage Tabakforsch. Int., Vol. 21, pp. 305-320 (2005); and Staaf et al., Beitrage Tabakforsch. Int., Vol. 21, pp. 321-330 (2005), which are incorporated herein by reference. Certain types of tobacco can be subjected to alternative types of curing processes, such as flame-curing or sun-curing.

[0158] 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.

[0159] 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.

[0160] 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. Patent No. 8,061,362 to Mua et al., which is incorporated herein by reference. In some 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 U.S. Patents 8,434,496, 8,944,072, and 8,991,403 to Chen et al., all of which are incorporated herein by reference. In some embodiments, this type of treatment is useful when the original tobacco material is subjected to heat in the previously described processes.

[0161] 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, in some embodiments, can 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. Patents 787,611 to Daniels, Jr.; 1,086,306 to Oelenheinz; 1,437,095 to Delling; 1,757,477 to Rosenhoch; 2,122,421 to Hawkinson; 2,148,147 to Baier; 2,170,107 to Baier; 2,274,649 to Pratz et al.; and 2,777 to Pratz et al., all of which are incorporated herein by reference. 70,239; Rosen, 3,612,065; Rosen, 3,851,653; Rosen, 3,889,689; Minami, 3,943,940; Rosen, 3,943,945; Rainer, 4,143,666; Campbell, 4,194,514; Rainer et al., 4,366,823, 4,366,824, and 4,388,933; Schmekel et al., 4,641,667; Berger, 5,713,376; Byrd Jr. et al., 9,339,058; Beeson et al., 9,420,825, and 10,772,349; and Byrd Jr. et al., U.S. Patent Application Publication Nos. 2012 / 0067361; 2016 / 0073686 to Crooks; 2017 / 0020183 to Bjorkholm; and 2017 / 0112183 to Bjorkholm; and International Publication Nos. WO 1996 / 031255 to Giolvas; WO 2020128971 and WO 2021048769 to McClanahan et al.; WO 2013122948 Al to Beeson et al.; WO 2018 / 083114 to Bjorkholm; and WO 2021048768 and WO 2021048770 Al to Zawadzki et al.

[0162] 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 ranging from about 50% to about 90%, from about 55% to about 75%, or from about 60% to about 70%. ISO brightness can be measured according to ISO 3688:1999 or ISO 2470-1:2016.

[0163] In some embodiments, whitened tobacco materials can be characterized by a lighter color (e.g., "whitened") compared to untreated tobacco materials. White color is often defined with reference to the International Commission on Illumination's (CIE's) chromaticity diagram. Whitened tobacco materials, in some embodiments, can be characterized as being closer to pure white on the chromaticity diagram than untreated tobacco materials.

[0164] Tobacco materials can also be treated to remove at least a portion of the nicotine present. Suitable methods for extracting nicotine from tobacco materials are known in the art. In some embodiments, the tobacco material is substantially free of nicotine. "Substantially free" means that only trace amounts are present in the tobacco material. For example, in some embodiments, the tobacco material can be characterized as having less than 0.001% nicotine by weight, or less than 0.0001% by weight, or even 0% nicotine by weight, calculated as the free base, based on the total weight of the tobacco material.

[0165] The amount of tobacco material present can vary and is generally less than about 65% by weight of the substrate and / or synthetic fibrous material, based on the total weight of the substrate and / or fibrous material. For example, the tobacco material can be present in an amount from about 0%, about 0.1%, about 0.5%, about 1%, about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, or about 35% by weight of the substrate and / or synthetic fibrous material, to about 40%, about 45%, about 50%, about 55%, about 60%, or about 65% by weight of the substrate and / or synthetic fibrous material, based on the total dry weight of the substrate and / or synthetic fibrous material.

[0166] In some embodiments, the substrate and / or synthetic fibrous material 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, some 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 and / or synthetic fibrous material.

[0167] <Tobacco extract> In some embodiments, the substrate and / or synthetic fibrous material 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., impregnated into the substrate during substrate preparation or after formation). As used herein, "tobacco extract" 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. Patent Application Publication No. 2011 / 0247640 to Beeson et al., incorporated herein by reference.Other exemplary techniques for extracting tobacco components are disclosed in U.S. Patents 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; and 4,588 to Keritsis, all of which are incorporated herein by reference. 9,428; Soga et al. 4,605,016; Poulose et al. 4,716,911; 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 g's 5,065,775; White et al.'s 5,074,319; White et al.'s 5,099,862; White et al.'s 5,121,757; Fagg's 5,131,414; Munoz et al.'s 5,131,415; Fagg's 5,148,819; Kramer's 5,197,494; Smith et al.'s 5,230,354; Fagg's 5,234,008; Smith's 5,243,999; Raymond et al.'s 5,30 1,694; Gonzalez-Parra et al., 5,318,050; Teague, 5,343,879; Newton, 5,360,022; Clapp et al., 5,435,325; Brinkley et al., 5,445,169; Lauterbach, 6,131,584; Kierulff et al., 6,298,859; Mua et al., 6,772,767; and Thompson, 7,337,782.

[0168] <Acid component> In some embodiments, the substrate and / or synthetic fibrous material includes an acid component. The presence of either an acid component or an acid salt of nicotine in the substrate and / or synthetic fibrous material can improve the sensory attributes of the aerosol, for example, by reducing the irritating properties of the aerosol when nicotine is present in the substrate and / or fibrous material. When present, the acid protonates the nicotine to form a nicotine salt in situ, i.e., either within the substrate and / or synthetic fibrous material or within the aerosol after it is formed. The presence of a nicotine salt produces an aerosol that some users find more satisfying. Furthermore, the presence of the acid reduces or substantially prevents evaporation of nicotine during preparation (e.g., drying) of the substrate and / or synthetic fibrous material, thereby reducing nicotine loss during manufacturing.

[0169] The amount of acid present in the substrate and / or synthetic fibrous material can vary, for example, from 0% to about 20% by weight, based on the dry weight of the substrate and / or fibrous material. In some embodiments, the substrate and / or fibrous material includes an acid in a molar ratio to nicotine. In some embodiments, the molar ratio of nicotine to acid is 2.2:1 or less, e.g., 1.5:1 or less, or 1:1 or less. In some embodiments, the molar ratio of nicotine to acid is 0.5:1 or greater.

[0170] In some embodiments, the acid comprises an acidic functional group having a pKa value, measured at 25° C., in the range of about 2 to about 6, e.g., a pKa value of 3 to 6 or 4 to 5. In some embodiments, the acid can be a monobasic acid, a dibasic acid, a tribasic acid, or a combination thereof.

[0171] In some embodiments, the acid is an organic acid. In some embodiments, the organic acid is a carboxylic acid. In some embodiments, the carboxylic acid comprises at least one carboxyl functional group. In some embodiments, the carboxylic acid is a monocarboxylic acid, a dicarboxylic acid, or a tricarboxylic acid. In some embodiments, the carboxylic acid further comprises an alpha hydroxy group. In some embodiments, the carboxylic acid further comprises a keto group.

[0172] 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.

[0173] In some 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.

[0174] <Other ingredients> In some embodiments, the substrate and / or synthetic fibrous material can further comprise a flame retardant material, conductive fibers or particles for heat conduction / induction, 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 and / or synthetic fibrous material, 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. In each embodiment of the flame retardant, flame retardant, and / or scorch retardant materials used in the substrate material and / or fibrous material or other components (whether they are used alone or in combination with each other and / or other materials), the desirable property is freedom from and resistance to undesirable off-gassing or melting-type behavior. Various modes and methods for incorporating tobacco into smoking articles, particularly for incorporating tobacco into smoking articles designed to intentionally not burn substantially all of the tobacco within those smoking articles, are described in U.S. Patent No. 4,947,874 to Brooks et al.; U.S. Patent No. 7,647,932 to Cantrell et al.; U.S. Patent No. 8,079,371 to Robinson et al.; U.S. Patent No. 7,290,549 to Banerjee et al.; and U.S. Patent Application Publication No. 2007 / 0215167 to Crooks et al., the disclosures of which are incorporated herein by reference in their entireties.

[0175] The substrate and / or synthetic fibrous material 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 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 and / or fibrous material to facilitate inductive heating at different temperatures.

[0176] In still other implementations, the substrate 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) and / or structured (e.g., wire mesh).

[0177] <Packaging materials> As described hereinafter, exemplary embodiments of consumables of the present disclosure include one or more wrapping materials surrounding all or a portion of the substrate. Exemplary wrapping material layers are shown as overwrap 112 in FIG. 6 and cover layers 132, 134, and 136 in FIG. 10. Such wrapping materials are typically constructed of paper or other cellulosic fibrous materials, such as wrapping materials used in conventional smoking articles. In various embodiments, the paper material can include wood fiber or rag fiber, such as non-wood plant fibers, including flax, hemp, sisal, rice straw, and / or esparto fiber.

[0178] In various embodiments, the packaging material can incorporate a fibrous material and, optionally, at least one filler material embedded or dispersed within the fibrous material. The filler material can, for example, have the form of essentially water-insoluble particles. Additionally, the filler material can incorporate inorganic components.

[0179] In some embodiments, the synthetic fibrous material can be associated with the packaging material. For example, the synthetic fibrous material can be formed into a sheet and adhered or laminated to the packaging material sheet. Alternatively, the synthetic fibrous material can be shredded or ground into a particulate material and added to the surface of the packaging material. Furthermore, the synthetic fibrous material can be deposited directly onto the surface of the packaging material during production of the synthetic fibrous material. For example, the synthetic fibrous material can be electrospun into fibers that are collected on the surface of the packaging material.

[0180] <Formation of substrate> In some embodiments, synthetic fibrous materials can be used as substrate materials without further incorporating filler materials. For example, synthetic fibrous materials can be deposited directly onto a support, such as support 40 depicted in FIG. 4 . Alternatively, in some embodiments, synthetic fibrous materials are associated with other substrate materials, such as other filler components disclosed herein. For example, synthetic fibrous materials can be formed into sheets or glued or laminated to a substrate sheet. Alternatively, synthetic fibrous materials can be shredded or ground into particulate materials that can be mixed with other substrate materials or added to the surface of a substrate. Furthermore, synthetic fibrous materials can be deposited directly onto the surface of a substrate during production of the fibrous material. For example, the fibrous material can be electrospun into fibers that collect on the surface of the substrate. FIG. 3 illustrates an embodiment of a substrate 22 having a base substrate layer 24 with an upper layer 26 of synthetic fibrous material deposited or laminated onto the base substrate layer.

[0181] 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.

[0182] 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 are described in U.S. Patent No. 4,674,519 to Keritsis; U.S. Patent No. 4,941,484 to Clapp et al.; U.S. Patent No. 4,987,906 to Young et al.; U.S. Patent No. 4,972,854 to Kiernan et al.; U.S. Patent No. 5,099,864 to Young et al.; U.S. Patent No. 5,143,097 to Sohn et al.; U.S. Patent No. 5,159,942 to Brinkley et al.; U.S. Patent No. 5,322,076 to Brinkley et al.; U.S. Patent No. 5,339,838 to Young et al.; U.S. Patent No. 5,377,698 to Litzinger et al.; U.S. Patent No. 5,501,237 to Young; and U.S. Patent No. 6,216,706 to Kumar, the disclosures of which are incorporated herein by reference in their entireties. In some embodiments, the flat sheet can be further reduced into scored lugs or strips for insertion into the substrate receiving segment of an aerosol delivery device. The cast sheet may also be collected or wound onto a rod for insertion into the substrate-receiving segment of an aerosol delivery device. The cast sheet may be glued or otherwise attached to a support.

[0183] 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. The thicknesses specified herein are average thicknesses for the sheets. In some cases, the thickness of the sheets may vary by no more than 25%, no more than 20%, no more than 15%, no more than 10%, no more than 5%, or no more than 1%.

[0184] In some embodiments, the flat sheet is layered in a series of overlapping layers 130, as illustrated in Figures 7 and 10, for example. In some embodiments, the flat sheet may be bunched, rolled, crimped, and / or gathered. In some embodiments, the flat sheet may be further reduced into scored lugs or strips for insertion into a substrate-containing segment of an aerosol delivery device. The flat sheet may also be gathered 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 may be stripped. 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 some embodiments.

[0185] In some embodiments, the individual strips or pieces of substrate have a minimum thickness of about 0.015 mm across their entire area. In some cases, the individual strips or pieces of substrate have a minimum thickness of about 0.05 mm or about 0.1 mm across their entire area. In some cases, the individual strips or pieces of substrate have a maximum thickness of about 1.0 mm across their entire area. In some cases, the individual strips or pieces of substrate have a maximum thickness of about 0.5 mm or about 0.3 mm across their entire area.

[0186] In some examples, a substrate in sheet form can have a tensile strength of about 150 N / m to about 3000 N / m, e.g., 150 N / m to 2500 N / m, or 150 N / m to 2000 N / m, or 200 N / m to 1700 N / m, or 250 N / m to 1500 N / m, or 200 N / m to 900 N / m. In some embodiments, the substrate 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 appropriate for embodiments in which the substrate is formed as a sheet and then stripped and incorporated into an aerosol generating element.

[0187] 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 about 800 N / m or greater. In some cases, 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 contained within the aerosol generation element as a rolled-up sheet, suitably in the form of a tube.

[0188] 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 to form blends, if desired, such as with shredded or particulate tobacco material or other non-tobacco substrate materials.

[0189] The various components of the base material can be contacted, combined, or mixed together using any mixing technique or device known in the art. Any mixing method that allows the base material components to come into intimate contact can be used, such as a mixing device equipped with an impeller or other agitating structure. 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, and the like. See also, for example, the types of methodologies described in U.S. Patents 4,148,325 to Solomon et al.; 6,510,855 to Korte et al.; and 6,834,654 to Williams, each of which is incorporated herein by reference. The manner and method for blending the mixture will be apparent to those skilled in the art. See, for example, the types of methodologies described in U.S. Pat. No. 4,148,325 to Solomon et al.; U.S. Pat. No. 6,510,855 to Korte et al.; and U.S. Pat. No. 6,834,654 to Williams, U.S. Pat. No. 4,725,440 to Ridgway et al., and U.S. Pat. No. 6,077,524 to Bolder et al., each of which is incorporated herein by reference.

[0190] 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.

[0191] In various embodiments, loading of the substrate with the aerosol-forming material depends on the location of the aerosol-forming material within the substrate. When the aerosol-forming material is within a synthetic fibrous material, such material is typically mixed with a polymer solution prior to fiber formation as described above. When the aerosol-forming material is intended to be present in other portions of the substrate (e.g., base substrate layer 24 in FIG. 3 ), loading is typically 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, such as one 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 or disposed within or on the substrate material in sheet form). In some embodiments, the aerosol-forming material may also be impregnated into the substrate, either with the substrate-forming slurry or as a surface treatment. Methods for loading a substrate portion with an aerosol-forming material are described in U.S. Patent No. 9,974,334 to Dooly et al. and U.S. Patent Application Publication 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 of ordinary skill in the art would recognize, multiple variations in the method for loading a substrate with an aerosol-forming material can occur depending on the particular substrate material, morphology, etc. Accordingly, any such modifications are contemplated herein.

[0192] Aerosol-Generating Elements and Aerosol-Delivery Devices The substrates and packaging materials according to some embodiments of the present disclosure can be used in the aerosol delivery device or aerosol generating element. Accordingly, a further exemplary embodiment of the present disclosure relates to an aerosol delivery device including an aerosol generating element including the substrate disclosed herein; a heat source configured to heat an aerosol-forming material carried in the substrate portion to form an aerosol; and an aerosol path extending from the aerosol generating element to the mouth end of the aerosol delivery device. The individual elements and construction of the aerosol generating element and aerosol delivery device are provided herein below.

[0193] The aerosol-generating elements of certain exemplary aerosol delivery devices can provide many of the sensations of cigarette, cigar, or pipe smoking (e.g., those provided by the inhalation and exhalation ritual, taste or flavor types, organoleptic effects, physical sensations, usage rituals, visual cues, e.g., visible aerosol, etc.) obtained by lighting and burning tobacco (and thus inhaling tobacco smoke), without any substantial degree of combustion of any of the components thereof. For example, a user of an aerosol delivery device according to some exemplary embodiments of the present disclosure can hold and use the component 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.

[0194] Although the present system is generally described herein in terms of embodiments relating to aerosol delivery devices and / or aerosol generating elements, e.g., so-called "e-cigarettes" or "heated tobacco products," it should be understood that the mechanisms, elements, 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, elements, 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.

[0195] 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.

[0196] The various substrate materials, aerosol generating elements, and more specific formats, configurations, and arrangements of elements 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 elements is recognized in light of commercially available electronic aerosol delivery devices. Furthermore, the arrangement of elements within the aerosol delivery device is also recognized in light of commercially available electronic aerosol delivery devices.

[0197] Substrates according to some 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 a substance for inhalation (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. Elements of such systems have the form of articles small enough to be considered handheld devices. That is, use of certain exemplary aerosol delivery device elements does not result in the production of smoke, in the sense that the aerosol is produced primarily from 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.

[0198] Thus, in some embodiments, the aerosol generating element of the present disclosure may generally include an ignitable heat source configured to heat a substrate material 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 resemble that of a traditional cigarette or cigar. The substrate material and / or any encasement element of the aerosol generating element may include a synthetic fibrous material disclosed herein.

[0199] Substrates according to some embodiments of the present disclosure can be used in the aerosol-generating element of an aerosol delivery device (e.g., an electrically heated tobacco product) 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. 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 element (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 elements of the article, e.g., a microprocessor), a heat source (e.g., an electrically resistive heating element or other element and / or an inductive coil or other associated element and / or one or more radiative 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 above-described elements can be physically combined. For example, in some embodiments, conductive heater traces can be printed onto the surface of a substrate material (e.g., a sheet or film) as described herein using conductive inks such that the heater traces can be activated 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.

[0200] In various embodiments, several of these elements can be provided within 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 elements of the aerosol delivery device are contained within a single housing or body. In some embodiments, the aerosol delivery device can include two or more joined, separable housings. For example, the aerosol delivery device can have an outer body or shell housing a disposable portion (e.g., a disposable flavor-containing aerosol generating element) at one end and a control device including a housing housing one or more reusable elements (e.g., an accumulator, e.g., a rechargeable battery and / or a rechargeable supercapacitor, and various electronics for controlling the operation of the item) at the other end, which can be removably connected thereto.

[0201] 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, such as additional tobacco material, tobacco-derived material, etc. (referred to herein as "aerosol-generating materials") mixed with the substrate. Such aerosol generating elements can also be referred to herein as "consumables," which means articles that include or consist of a substrate as described herein, some or all of which are intended to be consumed by a user during use.

[0202] In some embodiments, the aerosol-generating element comprises a substrate 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 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 in a layered form, comprising multiple sheets (layers) of substrate.

[0203] In some embodiments, the aerosol generating element further comprises a support. In some embodiments, the substrate is attached or adhered to the support. In some embodiments, the support is planar. A non-limiting embodiment of an aerosol generating element comprising a support and a substrate attached or adhered thereto is illustrated in Figure 4. Referring to Figure 4, the aerosol generating element 30 comprises a support 40 and a substrate 50 disposed thereon.

[0204] The support 40 may be at least partially porous in a surface region adjacent to the substrate 50. Conversely, a surface of the support 40 remote from the substrate 50 may be placed in contact with a heat source as described herein. In some embodiments, the support 40 may be a laminate structure. For example, the support 40 may include a cardboard-backed foil, where the cardboard layer is adjacent to the substrate 50. The foil backing is substantially impermeable and provides aerosol flow path control. The metal foil backing may also function to conduct heat to the substrate 50. In some embodiments, the foil layer of the cardboard-backed foil is adjacent to the substrate 50. The foil is substantially impermeable, thereby preventing moisture in the substrate 50 from being absorbed by the cardboard, which could weaken its structural integrity. In some embodiments, the support 40 is formed from or includes a metal foil, such as aluminum foil. The metal support may allow for improved conduction of thermal energy to the substrate. Additionally or alternatively, the metal foil can function as a susceptor in an induction heating system. In certain embodiments, the support 40 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.

[0205] Aerosol generating elements and aerosol delivery devices that include the substrates disclosed herein and that use heat from combustion or heat from electrical energy to provide the aerosol are further described herein below with reference to Figures 4-9.

[0206] In this regard, FIG. 5 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 may also allow for relatively precise control of the temperature range applied to the aerosol-forming material, especially when time-based current control is utilized. Useful conductive materials are typically chemically non-reactive with the materials being heated (e.g., the aerosol-forming material and other inhalable substance materials) so as not to adversely affect the flavor or content of the aerosol or vapor produced. Some exemplary, non-limiting materials that can be used as conductive materials include carbon, graphite, carbon / graphite composites, metals, ceramics, such as metal and non-metal carbides, nitrides, oxides, silicides, intermetallic compounds, cermets, metal alloys, and metal foils. Refractory materials may be particularly useful. Various different materials can be blended to achieve desired properties of resistivity, mass, and thermal conductivity. In some embodiments, metals that can be used include, for example, nickel, chromium, nickel-chromium alloys (e.g., nichrome), and steel.Materials that may be useful for providing resistive heating are described in U.S. Pat. No. 5,060,671 to Counts et al.; U.S. Pat. No. 5,093,894 to Deevi et al.; U.S. Pat. No. 5,224,498 to Deevi et al.; U.S. Pat. No. 5,228,460 to Sprinkel Jr. et al.; U.S. Pat. No. 5,322,075 to Deevi et al.; U.S. Pat. No. 5,353,813 to Deevi et al.; U.S. Pat. No. 5,468,936 to Deevi et al.; U.S. Pat. No. 5,498,850 to Das; U.S. Pat. No. 5,659,656 to Das; U.S. Pat. No. 5,498,855 to Deevi et al.; U.S. Pat. No. 5,530,225 to Hajaligol; U.S. Pat. No. 5,665,262 to Hajaligol; U.S. Pat. No. 5,573,692 to Das et al.; and U.S. Pat. No. 5,591,368 to Fleischhauer et al., the disclosures of which are incorporated herein by reference in their entireties.

[0207] 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 configured to generate heat as a result of electrical resistance associated with passing an electric current therethrough. Such resistive heating elements may be positioned proximate to and / or in direct contact with the substrate portion. For example, in one embodiment, the heating element may comprise a cylinder or other heating device 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 heating end 106 of the aerosol generation element 104, including the substrate portion 110. In this manner, the heating element can be positioned proximate the substrate portion 110 of the aerosol generating element 104 when the aerosol generating element 104 is inserted into the control device 102. In other examples, at least a portion of the heating element can penetrate at least a portion of the aerosol generating element (e.g., one or more protrusions and / or spikes that penetrate the aerosol generating element) when the aerosol generating element is inserted into the control device. Note that while in some embodiments the heating element can comprise a cylinder, in some embodiments the heating element can take various forms and in some embodiments can directly contact and / or penetrate the substrate portion. In addition to being configured for use with a conductive heat source as described above, the aerosol generating elements disclosed herein can also be configured for use with an inductive heat source to heat the substrate portion and 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 within the control device 102. In some embodiments, the resonant receiver, or a portion thereof, can be located within 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 a substrate portion. In some embodiments, the aerosol generation element is in intimate contact with the resonant receiver.

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

[0209] In various embodiments, the aerosol generation element 104 and the control device 102 may be permanently or separably aligned in operative relationship. In this regard, Figure 5 illustrates the aerosol delivery device 100 in a coupled configuration, while Figure 5 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.

[0210] 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 can be defined as a substantially rod-like, substantially tubular, or substantially cylindrical shape. In the embodiment of FIGS. 4-5, 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 sub-elements) can have a substantially rectangular shape, such as a substantially rectangular cubic shape (e.g., a shape similar to a USB flash drive). In some embodiments, one or both of the control device 102 or the aerosol generation element 104 (and / or any sub-elements) 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 elements, including the control device 102 and the aerosol-generating element 104.

[0211] The arrangement of elements 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., the aerosol-forming material therein) and form an aerosol for delivery to the user. When the heat source heats the substrate portion, an aerosol is formed, released, or generated in a physical form suitable for inhalation by the consumer. It 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.

[0212] 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 U.S. Pat. No. 9,484,155 to Peckerar et al. and U.S. Patent Application Publication No. 2017 / 0112191 to Sur et al., the disclosures of each of which are incorporated by reference herein in their entirety.

[0213] In some 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 connection to a car charger (i.e., a cigarette lighter case), and a connection to a computer, e.g., via a Universal Serial Bus (USB) cable or connector (e.g., USB 2.0, 3.0, 3.1, USB Type-C), a connection to a solar cell (sometimes called a solar cell) or solar panel, a wireless charger, e.g., a charger using inductive wireless charging (e.g., including wireless charging according to the Wireless Power Consortium (WPC) Qi wireless charging standard), or a wireless radio frequency (RF)-based charger. An example of an inductive wireless charging system is described in U.S. Patent Application Publication No. 2017 / 0112196 to Sur et al., which is incorporated herein by reference in its entirety. Additionally, in some embodiments, the aerosol generation element 104 can include a single-use device. Single-use elements for use with a control device are disclosed in U.S. Patent No. 8,910,639 to Chang et al., which is incorporated herein by reference in its entirety.

[0214] In a further embodiment, the power source can also include a capacitor. The capacitor can discharge faster than a battery and can become 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 element that can be attached to the smoking article between uses to replenish the supercapacitor.

[0215] Additional elements 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 regulators, and other current control elements, including various microcontrollers, sensors, and switches for aerosol delivery devices, are described in U.S. Patent No. 4,735,217 to Gerth et al., U.S. Patents Nos. 4,922,901, 4,947,874, and 4,947,875, all to Brooks et al., U.S. Patent No. 5,372,148 to McCafferty et al., U.S. Patent No. 6,040,560 to Fleischhauer et al., U.S. Patent No. 7,040,314 to Nguyen et al., and U.S. Patent No. 8,205,622 to Pan, all of which are incorporated herein by reference in their entirety. See also the control scheme described in U.S. Patent No. 9,423,152 to Ampolini et al., which is incorporated herein by reference in its entirety.

[0216] In another example, the aerosol delivery device can include a first conductive surface configured to contact a first body part of a user holding the device and a second conductive surface conductively separated from the first conductive surface and configured to contact a second body part of the user. Thus, when the aerosol delivery device detects a change in conductivity between the first 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 housed 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. Patent No. 9,861,773 to Terry et al., incorporated herein by reference in its entirety.

[0217] Additionally, U.S. Patent No. 5,154,192 to Sprinkel et al. discloses an indicator for a smoking article. U.S. Patent No. 5,261,424 to Sprinkel, Jr. discloses a piezoelectric sensor that can be associated with the mouth end of a device that detects the user's lip activity associated with taking a puff and then triggers heating of the heating device. U.S. Patent No. 5,372,148 to McCafferty et al. discloses a puff sensor for controlling the flow of energy to a heat load array in response to a pressure drop through a mouthpiece. U.S. Patent No. 5,967,148 to Harris et al. discloses a receptacle in a smoking device that includes an identifier that detects non-uniformity in the infrared transmittance of an inserted component and a controller that executes a detection routine when the component is inserted into the receptacle. U.S. Patent No. 6,040,560 to Fleischhauer et al. describes a defined executable power cycle with multiple differential phases. U.S. Patent No. 5,934,289 to Watkins et al. discloses a photonic-optronic element. U.S. Patent No. 5,954,979 to Counts et al. discloses a means for modifying the resistance to draw through a smoking device. U.S. Patent No. 6,803,545 to Blake et al. discloses specific battery configurations for use in smoking devices. U.S. Patent No. 7,293,565 to Griffen et al. discloses various charging systems for use with smoking devices. U.S. Patent No. 8,402,976 to Fernando et al. discloses a computer interface means for a smoking device that facilitates charging and allows computer control of the device. U.S. Patent No. 8,689,804 to Fernando et al. discloses an identification system for a smoking device. International Publication WO 2010 / 003480 to Flick discloses a fluid flow detection system that indicates puffs in an aerosol generating system. All of the foregoing disclosures are incorporated herein by reference in their entirety.

[0218] Further examples of elements related to electronic aerosol delivery articles and disclosed materials or elements that can be used in the devices of the present invention include U.S. Pat. No. 4,735,217 to Gerth et al.; U.S. Pat. No. 5,249,586 to Morgan et al.; U.S. Pat. No. 5,666,977 to Higgins et al.; U.S. Pat. No. 6,053,176 to Adams et al.; U.S. Pat. No. 6,164,287 to White; U.S. Pat. No. 6,196,218 to Voges; U.S. Pat. No. 6,810,883 to Felter et al.; U.S. Pat. No. 6,854,461 to Nichols; U.S. Pat. No. 7,832,410 to Hon; U.S. Pat. No. 7,513,253 to Kobayashi; U.S. Pat. No. 7,513,253 to Hamano; and U.S. Pat. No. 6,854,461 to Nichols; U.S. Pat. No. 7,832,410 to Hon; U.S. Pat. No. 7,513,253 to Kobayashi; and U.S. Pat. No. 6,854,461 to Nichols; U.S. Pat. No. 7,832,410 to Hon; U.S. Pat. No. 7,513,253 to Hamano; each of which is incorporated herein by reference in its entirety. US Patent No. 7,896,006; US Patent No. 6,772,756 to Shayan; US Patent Nos. 8,156,944 and 8,375,957 to Hon; US Patent No. 8,794,231 to Thorens et al.; US Patent No. 8,851,083 to Oglesby et al.; US Patent Nos. 8,915,254 and 8,925,555 to Monsees et al.; US Patent Nos. DePiano et al. No. 9,220,302; U.S. Patent Application Publication Nos. 2006 / 0196518 and 2009 / 0188490 to Hon; U.S. Patent Application Publication Nos. 2010 / 0024834 to Oglesby et al.; U.S. Patent Application Publication No. 2010 / 0307518 to Wang; International Publication No. WO 2010 / 091593 to Hon; and International Publication No. WO 2013 / 089551 to Foo. Additionally, U.S. Patent Application Publication No. 2017 / 0099877 to Worm et al. discloses encapsulations that may be included in aerosol delivery devices and fob-shaped 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.

[0219] Referring to FIG. 6 , in the illustrated embodiment, the aerosol generating element 104 includes a heated end 106 (configured to be inserted into the control device 102) and a mouth end 108 (where a user draws on the aerosol to create the 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, as described, for example, in U.S. Pat. No. 5,025,814 to Raker et al., which is incorporated herein by reference in its entirety. In various embodiments, the filter 114 can increase the structural integrity of the mouth end of the aerosol generation element 104 and / or provide filtering capabilities and / or resistance to draw, if desired. 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. The substrate portion 110 can include a synthetic fibrous material as disclosed herein.

[0220] In some embodiments, the material of the outer overwrap 112 can include a material that resists heat transfer, which can include paper or other fibrous materials, such as cellulosic materials. The outer overwrap material can also include at least one filler material embedded or dispersed within the fibrous material. In various embodiments, the filler material can have the form of water-insoluble particles. Additionally, the filler material can incorporate inorganic components. In various embodiments, the outer overwrap can be formed of multiple layers, such as an underlying, bulk, 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, to provide space for positioning a filter material as described below, to affect inhalation of the article, or to affect the flow characteristics of vapor or aerosol escaping 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. Patent No. 9,078,473 to Worm et al., which is incorporated herein by reference in its entirety. The overwrap 112 can include synthetic fibrous materials as disclosed herein. In some embodiments, the aerosol generating element and control device are typically provided together as a complete aerosol delivery article, although these elements may also be provided separately. For example, the present disclosure also encompasses disposable units for use with reusable smoking articles or reusable pharmaceutical delivery articles. In some embodiments, such a disposable unit (which may be an aerosol generating element as illustrated in the attached figures) may include a substantially tubular-shaped body having a heated end configured to engage a reusable aerosol delivery article, an opposing mouth end 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 US Pat. No. 9,078,473 to Worm et al., which is incorporated herein by reference in its entirety.

[0221] Although some figures described herein depict the controller and aerosol generation element in operative relationship, it is understood that the controller and aerosol generation element can exist as separate devices, and therefore, any discussion provided elsewhere herein relating to these elements in combination should also be understood to apply to the controller and aerosol generation element as individual and separate elements.

[0222] In another aspect, the present disclosure may be directed to a kit providing various elements 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 elements. The kit may further include a control device having one or more batteries. The kit may further include one or more aerosol generating elements and a control device having one or more charging elements 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 elements. In the above embodiments, the aerosol generating element or the control device may include a heating element therein. The kit may further include a case (or other packaging, shipping, or storage element) for housing one or more additional kit elements. The case may be a reusable rigid or flexible container. Furthermore, the case may simply be a box or other packaging structure.

[0223] 7 illustrates a schematic perspective view of an aerosol generating element according to an exemplary embodiment of the present disclosure. In particular, FIG. 7 illustrates an aerosol generating element 104 having a substrate portion 110 including a series of overlapping layers 130 of substrate in sheet form 120. Referring to the above description of the illustrated embodiment, the substrate sheet 120 includes a film or layer disclosed herein. In various embodiments, the term "overlapping layers" can also include bundled, rolled, crimped, and / or otherwise assembled layers where individual layers may not be apparent.

[0224] For example, Figure 10 illustrates a schematic cross-sectional view of a substrate portion 110 of an aerosol generation element 104 according to an exemplary embodiment of the present disclosure. In particular, Figure 10 illustrates the substrate portion 110, which includes a series of overlapping layers 130 of a substrate sheet 120. In the illustrated embodiment, at least a portion of the overlapping layers 130 is substantially surrounded around its outer surface by a first cover layer 132. In various embodiments, the first cover layer 132 can be constructed via a casting process, such as the method described in U.S. Patent No. 5,697,385 to Seymour et al., the disclosure of which is incorporated herein by reference in its entirety.

[0225] In the illustrated embodiment, at least a portion of the overlapping layer 130 and the first cover layer 132 are substantially surrounded about their outer surfaces by an optional second cover layer 134. While the composition of the second cover layer 134 can vary, in the illustrated embodiment, the second cover layer 134 comprises a metal foil material, e.g., an 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 about its outer surfaces by the overlapping layer 130, the first cover layer 132, and the second cover layer 134. In the illustrated embodiment, the third cover layer 136 comprises a paper material, e.g., conventional cigarette paper. In various embodiments, the paper material can include rag fibers, such as non-wood plant fibers, and can include flax, hemp, sisal, rice straw, and / or esparto fibers. Any of the base sheet 120 or cover layers 132, 134, and 136 can include synthetic fibrous materials as disclosed herein.

[0226] 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.

[0227] Figure 8 illustrates a perspective view of an aerosol generating element according to another exemplary embodiment of the present disclosure, and Figure 9 illustrates a perspective view of the aerosol generating element of Figure 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 element 208, and a filter 212. In the illustrated embodiment, the intermediate element 208 and the filter 212 together include a mouthpiece 214. The substrate portion 210 can include any embodiment of the substrate material described herein and can take a variety of forms, including those described in Figure 10.

[0228] In various embodiments, the heat source 204 can be configured to generate heat upon ignition. In the illustrated embodiment, the heat source 204 has a generally cylindrical shape and includes a combustible fuel component incorporating a combustible carbonaceous material. In other embodiments, the heat source 204 can 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.

[0229] 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 that reduces 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 a variety of ways, but in the embodiment shown, the heat source 204 is extruded or compounded using crushed or powdered carbonaceous material, with a dry weight basis of approximately 0.5 g / cm 3 Larger, often around 0.7 g / cm 3 Larger, often about 1 g / cm 3It has a greater density. See, for example, the types of fuel source elements, 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 configurations, including, for example, a substantially cylindrical or 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 element. In various embodiments, the heat transfer element can be proximate to the heat source; in some embodiments, the heat transfer element can be located within or within the heat source. Some examples of heat transfer elements are described in U.S. Patent Application Publication No. 2019 / 0281891 to Hejazi et al., which is incorporated herein by reference in its entirety.

[0230] While in the illustrated embodiment, the grooves 216 in the heat source 204 are substantially equal in width and depth and substantially evenly distributed around the circumference of the heat source 204, 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 flutes 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. Patent No. 7,615,184 to Lobovsky, which is incorporated herein by reference in its entirety. 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. Patent No. 4,922,901 to Brooks et al., such as those disclosed in U.S. Patent Application Publication No. 2009 / 0044818 to Takeuchi et al., each of which is incorporated herein by reference in its entirety.

[0231] Generally, the heat source is positioned sufficiently close to the substrate portion having one or more aerosol-forming materials such that the 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 similarly provided for delivery to the user) can be delivered to the user through the mouthpiece. That is, when the heat source heats the substrate portion, the 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.

[0232] 7 and 8 , the outer wrapping 202, in some embodiments, comprises a synthetic fibrous material as disclosed herein. The outer wrapping 202 may be provided to engage or otherwise join at least a portion of the heat source 204 with at least a portion of the substrate portion 210 and the mouthpiece 214 together. In various embodiments, the outer wrapping 202 is configured to be retained in the wrapped position in any manner, including via adhesive, fasteners, or the like, allowing the outer wrapping 202 to remain in the wrapped position. Alternatively, in some other aspects, the outer wrapping 202 may be configured to be removable, if desired. For example, the outer wrapping 202 may be removed from the heat source 204, the substrate portion 210, and / or the mouthpiece 214 while the outer wrapping 202 remains in the wrapped position.

[0233] 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 material and / or an 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, may advantageously provide a way to engage two or more separate elements 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.

[0234] As shown in FIGS. 7-8 , 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 proximate the end of the substrate portion 210 closest to the heat source 204, and a plurality of separate cooling openings 221 are formed in the outer 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.

[0235] Referring again to Figures 7-8, the aerosol generating element 200 in the illustrated embodiment also includes an intermediate element 208 and at least one filter 212. Note that in various implementations, the intermediate element 208 or the filter 212, individually or together, may be considered the mouthpiece 214 of the aerosol generating element 200. While in various implementations neither an intermediate element nor a filter need be included, in the illustrated implementation, the intermediate element 208 comprises a substantially rigid member that is substantially inflexible along its longitudinal axis. In the illustrated implementation, the intermediate element 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 element 208 can be used as a container for collecting the aerosol. In various implementations, such elements can be constructed from any of a variety of materials and can include one or more adhesives. Exemplary materials include, but are not limited to, paper, paper layers, paperboard, plastic, cardboard, and / or composite materials. In the implementation shown, the intermediate element 208 comprises a cylindrical element constructed of paper or plastic material (e.g., ethyl vinyl acetate (EVA) or other polymeric material, such as polyethylene, polyester, silicone, etc., or ceramics (e.g., silicon carbide, alumina, etc.) or other acetate fibers), and the filter comprises a 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).

[0236] 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 element 208. In this manner, upon drawing on the mouthpiece 214, the filter 212 receives the aerosol flowing through the intermediate element 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. Patent No. 5,025,814 to Raker et al., which is incorporated herein by reference in its entirety.

[0237] In various implementations, the size and shape of intermediate element 208 and / or filter 212 may vary, for example, the length of intermediate element 208 may range from approximately 10 mm to approximately 30 mm (inclusive), the diameter of intermediate element 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 element 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).

[0238] In various implementations, ignition of the heat source 204 results in aerosolization of the aerosol-forming material associated with the substrate portion 210. In some embodiments, the components of the substrate portion 210 do not undergo thermal decomposition (e.g., charring, scorching, or burning) to any significant extent, and the aerosolized components are entrained in air drawn through the aerosol-generating element 200, including the filter 212, and into the user's mouth. In various implementations, the mouthpiece 214 (e.g., the intermediate element 208 and / or the filter 212) is configured to receive the generated aerosol therethrough in response to drawing on the mouthpiece 214 by the user. In some implementations, the mouthpiece 214 can be fixedly engaged to the substrate portion 210. For example, adhesives, bonding, welding, etc., can be suitable for fixedly engaging the mouthpiece 214 to the substrate portion 210. In one example, the mouthpiece 214 is ultrasonically welded and sealed to the end of the substrate portion 210.

[0239] 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.

[0240] Many modifications and other embodiments of the present disclosure will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. It is to be understood, therefore, that the disclosure is not limited to the specific embodiments disclosed herein, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms 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 consumable for use in an aerosol delivery device, the consumable comprising: a substrate comprising at least one aerosol-forming material; and At least one envelope material enveloping at least a portion of the substrate. Including, 1. An aerosol-generating consumable product, wherein at least one of the substrate and the envelope material comprises a plurality of synthetic fibers, each fiber comprising a polymer matrix encapsulating an aerosolizable additive.

2. 10. The aerosol generating consumable of claim 1, wherein the synthetic fibers are electrospun.

3. 10. The aerosol-generating consumable product of claim 1, wherein the aerosolizable additive comprises an aerosol-forming material, an active ingredient, a flavoring substance, or a combination thereof.

4. 4. The aerosol generating consumable product of claim 3, wherein the active ingredient is selected from the group consisting of nicotine components, botanical materials, stimulants, amino acids, vitamins, antioxidants, functional foods, cannabinoids, cannabimimetics, terpenes, pharmaceuticals, and combinations thereof.

5. 10. The aerosol generating consumable of claim 1, wherein the synthetic fibers are decomposable when exposed to heat.

6. 10. The aerosol generating consumable of claim 1, wherein the synthetic fibers are degradable when exposed to moisture.

7. 10. The aerosol generating consumable of claim 1, wherein the synthetic fibers are degradable when exposed to an enzyme.

8. 10. The aerosol-generating consumable product according to claim 1, wherein the aerosol-forming material is present in an amount of about 3% by weight or greater, based on the total weight of the substrate.

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

10. 10. The aerosol-generating consumable product according to claim 1, wherein the aerosol-forming material is present in an amount ranging from about 10% by weight to about 70% by weight, based on the total weight of the substrate.

11. 10. The aerosol-generating consumable product according to claim 1, wherein the aerosol-forming material is present in an amount ranging from about 30% to about 60% by weight, based on the total weight of the substrate.

12. 2. The aerosol-generating consumable product 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.

13. The aerosol-generating consumable product according to claim 1 , wherein the aerosol-forming material is a polyhydric alcohol.

14. 14. The aerosol generating consumable product according to claim 13, wherein the polyhydric alcohol is selected from the group consisting of glycerol, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, and combinations thereof.

15. 10. The aerosol generating consumable product according to claim 1, wherein the aerosol-forming material is glycerol.

16. 10. The aerosol generating consumable of claim 1, wherein the polymer matrix comprises a polymer selected from the group consisting of gelatin, agarose, polycaprolactone, chitosan, glucan, pullulan, zein, ethylcellulose, and combinations thereof.

17. 10. The aerosol-generating consumable according to claim 1, wherein the polymer matrix has a thermal decomposition temperature of at least about 250°C.

18. 10. The aerosol-generating consumable according to claim 1, wherein the polymer matrix has a thermal decomposition temperature of at least about 275°C.

19. 10. The aerosol-generating consumable according to claim 1, wherein the polymer matrix has a thermal decomposition temperature of at least about 300°C.

20. 10. The aerosol-generating consumable according to claim 1, wherein the polymer matrix has a thermal decomposition temperature of at least about 325°C.

21. 10. The aerosol-generating consumable product according to claim 1, wherein the polymer matrix has a thermal decomposition temperature between about 250°C and about 400°C.

22. 10. The aerosol generating consumable according to claim 1, wherein the polymer matrix has a melting point of at least about 100°C.

23. 10. The aerosol generating consumable according to claim 1, wherein the polymer matrix has a melting point of at least about 125°C.

24. 10. The aerosol generating consumable according to claim 1, wherein the polymer matrix has a melting point of at least about 150°C.

25. 10. The aerosol generating consumable according to claim 1, wherein the polymer matrix has a melting point of at least about 200°C.

26. 10. The aerosol-generating consumable product of claim 1, wherein the polymer matrix has a melting point between about 100°C and about 350°C.

27. The aerosol generating consumable of claim 1 , further comprising a support, the substrate being attached to the support.

28. 28. The aerosol generating consumable product of claim 27, wherein the support is planar.

29. The aerosol generating consumable product according to any one of claims 1 to 28. a heat source configured to heat the substrate to form an aerosol; and an aerosol pathway extending along a length extending from the substrate and configured to convey the aerosol to the mouth of the aerosol delivery device; 1. An aerosol delivery device comprising:

30. 30. The aerosol delivery device of claim 29, wherein the heat source comprises either an electrically powered heating element or a combustible ignition source.

31. 31. The aerosol delivery device of claim 30, wherein the heat source is a combustible ignition source comprising a carbon-based material.

32. 31. The aerosol delivery device of claim 30, wherein the heat source is an electrically driven heating element.

33. 33. The aerosol delivery device of claim 32, further comprising a power source electronically connected to the heating element.

34. 34. The aerosol delivery device of claim 33, further comprising a controller configured to control power delivered by the power source to the heating element.

35. 30. The aerosol delivery device of claim 29, wherein the heat source is a conductive or inductive heat source.

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