Substrate with multiple aerosol forming materials for aerosol delivery device

Abstract

The present disclosure provides an aerosol generating component including a substrate impregnated with two or more aerosol forming materials, including a first aerosol forming material and a second aerosol forming material, wherein the first aerosol forming material and the second aerosol forming material each have different boiling points, different vapor pressures, or both. The disclosed aerosol generating component may be utilized in aerosol delivery devices such as heat not burn (HNB) or electrically heated aerosol delivery devices.

What is claimed is: 
     
         1 . An aerosol generating component comprising a substrate impregnated with two or more aerosol forming materials, including a first aerosol forming material and a second aerosol forming material, wherein the first aerosol forming material and the second aerosol forming material each have different boiling points, different vapor pressures, or both. 
     
     
         2 . The aerosol generating component of  claim 1 , wherein the first aerosol forming material and the second aerosol forming material are independently selected from the group consisting of water, polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, cannabinoids, terpenes, and sugar alcohols. 
     
     
         3 . The aerosol generating component of  claim 1 , wherein the two or more aerosol forming materials are present in a ratio by weight of the first aerosol forming material to the second aerosol forming material of from about 3:1 to about 1:3. 
     
     
         4 . The aerosol generating component of  claim 1 , wherein at least one of the first aerosol forming material and the second aerosol forming material is a polyhydric alcohol. 
     
     
         5 . The aerosol generating component of  claim 1 , wherein the first aerosol forming material and the second aerosol forming material are both polyhydric alcohols. 
     
     
         6 . The aerosol generating component of  claim 5 , wherein the polyhydric alcohols are selected from the group consisting of glycerol, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, and combinations thereof. 
     
     
         7 . The aerosol generating component of  claim 5 , wherein the polyhydric alcohols are glycerol and propylene glycol. 
     
     
         8 . The aerosol generating component of  claim 7 , wherein the glycerol and propylene glycol are present in a ratio by weight of from about 3:1 to about 1:3. 
     
     
         9 . The aerosol generating component of  claim 7 , wherein the glycerol and propylene glycol are present in a ratio by weight of about 1:1. 
     
     
         10 . The aerosol generating component of  claim 1 , wherein the substrate is further impregnated with at least one additional aerosol former. 
     
     
         11 . The aerosol generating component of  claim 10 , wherein the at least one additional aerosol former is selected from the group consisting of water, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, sugar alcohols, cannabinoids, terpenes, and combinations thereof. 
     
     
         12 . The aerosol generating component of  claim 1 , wherein the substrate is further impregnated with a flavorant, an active ingredient, or a combination thereof 
     
     
         13 . The aerosol generating component of  claim 12 , wherein the active ingredient comprises a tobacco component, a non-tobacco botanical, a nicotine component, or a combination thereof. 
     
     
         14 . The aerosol generating component of  claim 12 , wherein the active ingredient comprises a nicotine component. 
     
     
         15 . The aerosol generating component of  claim 1 , wherein the substrate is impregnated with the two or more aerosol forming materials at a loading of from about 15 to about 55% by weight, based on a total weight of the impregnated substrate. 
     
     
         16 . The aerosol generating component of  claim 1 , wherein the substrate is in particulate form, shredded form, film form, paper process sheet form, cast sheet form, bead form, granular rod form, or extrudate form. 
     
     
         17 . The aerosol generating component of  claim 16 , wherein the substrate is formed into a substantially cylindrical shape. 
     
     
         18 . The aerosol generating component of  claim 1 , wherein the substrate comprises tobacco-derived fibers, wood-derived fibers, or a combination thereof. 
     
     
         19 . The aerosol generating component of  claim 18 , wherein the substrate further comprises one or more binders. 
     
     
         20 . The aerosol generating component of  claim 19 , wherein the one or more binders are selected from alginates, cellulose derivatives, starches, gums, dextrans, carrageenan, calcium carbonate, or combinations thereof. 
     
     
         21 . The aerosol generating component of  claim 1 , wherein the substrate comprises one or more of calcium carbonate, an alginate, one or more cellulose derivatives, a starch, wood pulp, or tobacco-derived fibers. 
     
     
         22 . The aerosol generating component of  claim 21 , wherein the two or more aerosol forming materials are present in a ratio by weight of from about 3:1 to about 1:3. 
     
     
         23 . The aerosol generating component of  claim 22 , wherein the two or more aerosol forming materials are glycerol and propylene glycol. 
     
     
         24 . The aerosol generating component of  claim 1 , wherein the substrate comprises:
 from about 0 to about 5% by weight of calcium carbonate;   from about 1% to about 5% by weight of wood pulp;   from about 70 to about 80% by weight of tobacco-derived fibers; and   wherein the substrate is impregnated with the two or more aerosol forming materials at a loading of about 15 to about 25% by weight, based on a total weight of the impregnated substrate.   
     
     
         25 . The aerosol generating component of  claim 1 , wherein the substrate comprises:
 from about 45 to about 60% by weight of calcium carbonate;   from about 0 to about 10% by weight of an alginate;   from about 0 to about 5% by weight of one or more cellulose derivatives;   from about 0 to about 15% by weight of a starch;   from about 0 to about 5% by weight of wood pulp;   from about 0 to about 40% by weight of tobacco-derived fibers; and   wherein the substrate is impregnated with the two or more aerosol forming materials at a loading of from about 15 to about 25% by weight, based on a total weight of the impregnated substrate.   
     
     
         26 . The aerosol generating component of  claim 1 , wherein the substrate comprises:
 from about 40 to about 60% by weight of calcium carbonate;   from about 0 to about 10% by weight of an alginate;   from about 0 to about 5% by weight of one or more cellulose derivatives;   from about 0 to about 15% by weight of a starch;   from about 0 to about 5% by weight of wood pulp;   from about 0 to about 40% by weight of tobacco-derived fibers; and   wherein the substrate is impregnated with the two or more aerosol forming materials at a loading of from about 15 to about 25% by weight, based on a total weight of the impregnated substrate.   
     
     
         27 . The aerosol generating component of  claim 1 , wherein the substrate comprises:
 from about 5 to about 15% by weight of calcium carbonate;   from about 1 to about 5% by weight of one or more cellulose derivatives;   from about 20 to about 40% by weight of a starch;   from about 20 to about 40% by weight of tobacco-derived fibers; and   wherein the substrate is impregnated with the two or more aerosol forming materials at a loading of from about 15 to about 25% by weight, based on a total weight of the impregnated substrate.   
     
     
         28 . An aerosol delivery device, comprising:
 the aerosol generating component of  claim 1 ;   a heat source configured to heat the impregnated substrate to form an aerosol; and   an aerosol pathway extending from the aerosol generating component to a mouth-end of the aerosol delivery device.   
     
     
         29 . The aerosol delivery device of  claim 28 , wherein the heat source comprises either an electrically powered heating element or a combustible ignition source. 
     
     
         30 . The aerosol delivery device of  claim 28 , wherein the heat source is a combustible ignition source comprising a carbon-based material. 
     
     
         31 . The aerosol delivery device of  claim 28 , wherein the heat source is an electrically-powered heating element. 
     
     
         32 . The aerosol delivery device of  claim 31 , further comprising a power source electronically connected to the heating element. 
     
     
         33 . The aerosol delivery device of  claim 31 , further comprising a controller configured to control the power transmitted by the power source to the heating element.