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 selected from the group consisting of glycerol, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, a polyethylene glycol, triacetin, and combinations thereof; and   a second aerosol forming material different from the first aerosol forming material and selected from the group consisting of polysorbates, sorbitan esters, fatty acids, fatty acid esters, 1,3-propanediol, triethylene glycol, a polyethylene glycol, triacetin, waxes, cannabinoids, terpenes, and sugar alcohols;   wherein the first aerosol forming material and the second aerosol forming material each have different boiling points, different vapor pressures, or both; and   wherein the substrate is impregnated with the two or more aerosol forming materials at a loading from about 5 to about 60% by weight, based on the total weight of the impregnated substrate.   
     
     
         2 . The aerosol generating component of  claim 1 , wherein the substrate is impregnated with the two or more aerosol forming materials at a loading from about 15 to about 30% by weight, based on a total weight of the impregnated substrate. 
     
     
         3 . The aerosol generating component of  claim 1 , wherein a ratio by weight of the first aerosol forming material to the second aerosol forming material is from about 100:1 to about 1:100. 
     
     
         4 . The aerosol generating component of  claim 1 , wherein a ratio by weight of the first aerosol forming material to the second aerosol forming material is from about 3:1 to about 1:3. 
     
     
         5 . The aerosol generating component of  claim 1 , wherein the second aerosol forming material is selected from the group consisting of palmitic acid, polyethylene glycol 400, sorbitan tristearate, polysorbate 80, and combinations thereof. 
     
     
         6 . The aerosol generating component of  claim 1 , wherein the first aerosol forming material is glycerol, and the second aerosol forming material is 1,3-propanediol, triethylene glycol, palmitic acid, or triacetin. 
     
     
         7 . The aerosol generating component of  claim 1 , wherein the first aerosol forming material is glycerol, and the second aerosol forming material is palmitic acid. 
     
     
         8 . The aerosol generating component of  claim 1 , wherein:
 the first aerosol forming material is 1,3-propanediol, triethylene glycol, propylene glycol, or triacetin; and   the second aerosol forming material is palmitic acid, polyethylene glycol 400, sorbitan tristearate, or polysorbate 80.   
     
     
         9 . The aerosol generating component of  claim 1 , wherein the substrate is impregnated with glycerol, palmitic acid, and a third aerosol forming material selected from the group consisting of 1,3-propanediol, triethylene glycol, propylene glycol, triacetin, polyethylene glycol 400, sorbitan tristearate, and polysorbate 80. 
     
     
         10 . The aerosol generating component of  claim 1 , wherein the substrate is impregnated with a mixture selected from the group consisting of:
 glycerol and palmitic acid;   glycerol and 1,3-propanediol;   glycerol and triethylene glycol;   glycerol and triacetin;   1,3-propanediol and palmitic acid;   1,3-propanediol and polyethylene glycol;   1,3-propanediol and polysorbate 80;   triethylene glycol and palmitic acid;   triethylene glycol and polyethylene glycol;   triethylene glycol and polysorbate 80;   triacetin and palmitic acid;   triacetin and polyethylene glycol;   triacetin and polysorbate 80;   propylene glycol and palmitic acid;   propylene glycol and polyethylene glycol; and   propylene glycol and polysorbate 80.   
     
     
         11 . The aerosol generating component of  claim 10 , wherein in each listed mixture, a ratio of the aerosol forming materials is from about 3:1 to about 1:3. 
     
     
         12 . The aerosol generating component of  claim 1 , wherein the substrate is impregnated with a mixture comprising glycerol, palmitic acid, and propylene glycol. 
     
     
         13 . The aerosol generating component of  claim 12 , further comprising triacetin. 
     
     
         14 . The aerosol generating component of  claim 1 , wherein the substrate further comprises water in an amount by weight of up to about 10%, based on the total dry weight of the impregnated substrate. 
     
     
         15 . The aerosol generating component of  claim 1 , wherein the substrate comprises tobacco-derived fibers, wood-derived fibers, plant or plant-derived fibers, synthetic fibers, or a combination thereof, and one or more binders. 
     
     
         16 . The aerosol generating component of  claim 1 , wherein the one or more binders are selected from alginates, cellulose derivatives, starches, gums, dextrans, carrageenan, calcium carbonate, or combinations thereof. 
     
     
         17 . The aerosol generating component of  claim 1 , wherein the substrate comprises:
 from about 40 to about 70% by weight of tobacco-derived fibers;   from about 10 to about 15% by weight of a cellulose derivative; and   from about 5 to about 10% by weight of wood pulp.   
     
     
         18 . The aerosol generating component of  claim 1 , wherein the substrate is further impregnated with a flavorant, an active ingredient, or a combination thereof. 
     
     
         19 . The aerosol generating component of  claim 18 , wherein the active ingredient comprises a tobacco component, a non-tobacco botanical, a nicotine component, or a combination thereof. 
     
     
         20 . The aerosol generating component of  claim 18 , wherein the active ingredient comprises a nicotine component. 
     
     
         21 . 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 form, rod form, or extrudate form. 
     
     
         22 . The aerosol generating component of  claim 21 , wherein the substrate is formed into a substantially cylindrical shape. 
     
     
         23 . 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.   
     
     
         24 . The aerosol delivery device of  claim 23 , wherein the heat source comprises either an electrically powered heating element or a combustible ignition source. 
     
     
         25 . The aerosol delivery device of  claim 24 , wherein the heat source is a combustible ignition source comprising a carbon-based material. 
     
     
         26 . The aerosol delivery device of  claim 24 , wherein the heat source is an electrically-powered heating element. 
     
     
         27 . The aerosol delivery device of  claim 26 , further comprising a power source electronically connected to the heating element. 
     
     
         28 . The aerosol delivery device of  claim 27 , further comprising a controller configured to control the power transmitted by the power source to the heating element.