Substrate material comprising beads for aerosol delivery devices

Abstract

The present disclosure provides a composite substrate configured for use in aerosol generating components for aerosol delivery devices. The composite substrate includes a first substrate material and a second substrate material attached thereto. The first substrate material includes a first filler, a first binder, and a first aerosol forming material, and the second substrate material includes a second filler and a second binder. Further provided are a process for making the composite substrate, and aerosol generating components and aerosol delivery devices including the composite substrate. Such devices utilize electrically generated heat or combustible ignition sources to heat the composite substrate, providing an inhalable substance in the form of an aerosol.

What is claimed is: 
     
         1 . A composite substrate configured for use in an aerosol delivery device, the composite substrate comprising:
 a first substrate material comprising a first filler, a binder, and an aerosol forming material; and   a second substrate material attached to the first substrate material, the second substrate material comprising a second filler, a second binder, and a second aerosol forming material.   
     
     
         2 . The composite substrate of  claim 1 , wherein the second substrate material is in the form of one or more beads, sphere, or rods adhered to, or imbedded within, the first substrate material. 
     
     
         3 . The composite substrate of  claim 1 , wherein the first substrate material is in the form of a sheet. 
     
     
         4 . The composite substrate of  claim 1 , wherein the first substrate material is in the form of a shredded or particulate material. 
     
     
         5 . The composite substrate of  claim 1 , wherein both the first substrate material and the second substrate material are in the form of sheets attached together in a layered configuration. 
     
     
         6 . The composite substrate of  claim 1 , wherein the first substrate material and the second substrate material have one or more of a different composition, a different density, and a different outer shape. 
     
     
         7 . The composite substrate of  claim 6 , wherein the density of the second substrate material is at least about 10% higher than the density of the first substrate material 
     
     
         8 . The composite substrate of  claim 1 , wherein the first substrate material comprises at least about 50% by weight of the first filler, based on the total dry weight of the first substrate material. 
     
     
         9 . The composite substrate of  claim 1 , wherein the first substrate material comprises from about 50% to about 75% by weight of the first filler, based on the total dry weight of the first substrate material. 
     
     
         10 . The composite substrate of  claim 1 , wherein the first filler and the second filler are independently selected from the group consisting of a tobacco material, a botanical material, wood pulp, a native or modified starch, maltodextrin, dextrose, calcium carbonate, a sugar alcohol, microcrystalline cellulose, and combinations thereof. 
     
     
         11 . The composite substrate of  claim 1 , wherein the first filler and the second filler are independently selected from the group consisting of a tobacco material, wood pulp, maltodextrin, calcium carbonate, and combinations thereof. 
     
     
         12 . The composite substrate of  claim 1 , wherein the first filler and the second filler are independently selected from the group consisting of wood pulp, maltodextrin, calcium carbonate, and combinations thereof. 
     
     
         13 . The composite substrate of  claim 1 , wherein the first binder and second binder comprise a cellulose ether independently selected from the group consisting of methylcellulose, hydroxypropyl cellulose (HPC), hydroxypropyl methylcellulose (HPMC), hydroxyethyl cellulose, carboxymethylcellulose (CMC), and combinations thereof. 
     
     
         14 . The composite substrate of  claim 1 , wherein the first binder and the second binder comprise CMC. 
     
     
         15 . The composite substrate of  claim 1 , wherein the first aerosol forming material and the second aerosol forming material are independently selected from the group consisting of water, a polyhydric alcohol, a polysorbate, a sorbitan ester, a fatty acid, a fatty acid ester, a wax, a cannabinoid, a terpene, a sugar alcohol, and combinations thereof. 
     
     
         16 . The composite substrate of  claim 1 , wherein the first aerosol forming material and the second aerosol forming material each comprise a polyhydric alcohol. 
     
     
         17 . The composite substrate of  claim 16 , wherein the polyhydric alcohol is selected from the group consisting of glycerin, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, triacetin, and combinations thereof. 
     
     
         18 . The composite substrate of  claim 1 , wherein the first substrate material comprises:
 a tobacco material in an amount from about 0 to about 70% by weight, based on the total wet weight of the first substrate material;   wood pulp in an amount from about 0 to about 10% by weight, based on the total wet weight of the first substrate material;   calcium carbonate in an amount from about 0 to about 30% by weight, based on the total wet weight of the first substrate material;   maltodextrin in an amount from about 0 to about 40% by weight, based on the total wet weight of the first substrate material;   glycerin in an amount from about 10 to about 20% by weight, based on the total wet weight of the first substrate material;   carboxymethylcellulose in an amount from about 5 to about 15% by weight, based on the total wet weight of the first substrate material; and   water in an amount up to about 30% by weight, based on the total wet weight of the first substrate material.   
     
     
         19 . The composite substrate of  claim 1 , wherein the first substrate material further comprises a flavorant, an active ingredient, a tobacco extract, or a combination thereof. 
     
     
         20 . The composite substrate of  claim 19 , wherein the active ingredient comprises a nicotine component. 
     
     
         21 . The composite substrate of  claim 2 , wherein the beads, sphere, or rods comprise at least about 50% by weight of the second filler, based on the total dry weight of the beads. 
     
     
         22 . The composite substrate of  claim 2 , wherein the beads, sphere, or rods comprise from about 50% to about 65% by weight of the second filler, based on the total dry weight of the beads. 
     
     
         23 . The composite substrate of  claim 2 , wherein the second filler comprises a tobacco material, a botanical material, calcium carbonate, or a combination thereof. 
     
     
         24 . The composite substrate of  claim 2 , wherein the second filler is selected from the group consisting of a tobacco material, calcium carbonate, and combinations thereof. 
     
     
         25 . The composite substrate of  claim 2 , wherein the second binder is selected from the group consisting of methylcellulose, hydroxypropyl cellulose (HPC), hydroxypropyl methylcellulose (HPMC), hydroxyethyl cellulose, carboxymethylcellulose (CMC), and combinations thereof. 
     
     
         26 . The composite substrate of  claim 25 , wherein the second binder is CMC. 
     
     
         27 . The composite substrate of  claim 2 , wherein the beads, spheres or rods comprise:
 a tobacco material in an amount from about 20 to about 40% by weight, based on the total dry weight of the beads, spheres or rods;   calcium carbonate in an amount from about 20 to about 40% by weight, based on the total dry weight of the beads, spheres or rods;   glycerin in an amount from about 0 to about 20% by weight, based on the total dry weight of the beads, spheres or rods; and   carboxymethylcellulose in an amount from about 0 to about 2% by weight, based on the total dry weight of the beads, spheres or rods.   
     
     
         28 . The composite substrate of  claim 2 , wherein the beads, spheres or rods further comprise a flavorant, an active ingredient, or a combination thereof. 
     
     
         29 . The composite substrate of  claim 2 , wherein the second aerosol forming material is selected from the group consisting of water, a polyhydric alcohol, a polysorbate, a sorbitan ester, a fatty acid, a fatty acid ester, a wax, a cannabinoid, a terpene, a sugar alcohol, and combinations of any thereof. 
     
     
         30 . The composite substrate of  claim 29 , wherein the polyhydric alcohol is selected from the group consisting of glycerol, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, triacetin, and combinations thereof. 
     
     
         31 . The composite substrate of  claim 2 , comprising from about 10 to about 50% by weight of the beads, spheres or rods, based on the total weight of the composite substrate. 
     
     
         32 . The composite substrate of  claim 2 , wherein the beads, spheres, or rods have a diameter in a range from about 0.1 mm to about 5 mm. 
     
     
         33 . The composite substrate of  claim 2 , wherein the beads, spheres or rods are adhered to the surface of the first substrate material in a randomly spaced pattern. 
     
     
         34 . The composite substrate of  claim 2 , wherein the beads, spheres or rods are adhered to the surface of the first substrate material in a uniformly spaced pattern. 
     
     
         35 . The composite substrate of  claim 1 , wherein the substrate is substantially free of wood fibers. 
     
     
         36 . The composite substrate of  claim 1 , wherein the substrate is substantially free of tobacco material. 
     
     
         37 . The composite substrate of  claim 1 , in the form of a flat sheet, a gathered sheet, multiple layered sheets, a rolled sheet, or in shredded form. 
     
     
         38 . The composite substrate of  claim 1  in shredded form, further comprising a tobacco material blended therewith. 
     
     
         39 . An aerosol delivery device, comprising:
 the composite substrate of  claim 1 ;   a heat source configured to heat the composite substrate to form an aerosol; and   an aerosol pathway extending from the composite substrate to a mouth-end of the aerosol delivery device.   
     
     
         40 . The aerosol delivery device of  claim 39 , wherein the heat source comprises either an electrically powered heating element or a combustible ignition source. 
     
     
         41 . The aerosol delivery device of  claim 40 , wherein the heat source is a combustible ignition source comprising a carbon-based material. 
     
     
         42 . The aerosol delivery device of  claim 40 , wherein the heat source is an electrically powered heating element. 
     
     
         43 . The aerosol delivery device of  claim 42 , further comprising a power source electronically connected to the heating element. 
     
     
         44 . The aerosol delivery device of  claim 43 , further comprising a controller configured to control the power transmitted by the power source to the heating element. 
     
     
         45 . A method of making a composite substrate configured for use in an aerosol delivery device, the method comprising:
 (a) preparing a slurry comprising a first filler, a first binder, and a first aerosol forming material;   (b) casting the slurry onto a supportive device to form a first substrate material in the form of a wet sheet;   (c) preparing a second substrate material comprising a second filler, a second binder, and a second aerosol forming material, wherein the second substrate material is in beaded form;   (d) depositing the second substrate material onto a surface of the first substrate material; and   (e) drying the first substrate material having deposited thereon the second substrate material in beaded form, to form the composite substrate, wherein the second substrate material in beaded form is adhered to a surface of the first substrate material substrate.   
     
     
         46 . The method of  claim 45 , wherein the slurry comprises:
 a tobacco or botanical material in an amount from about 0 to about 70% by weight, based on the total wet weight of the slurry;   wood pulp in an amount from about 0 to about 10% by weight, based on the total wet weight of the slurry;   an additional first filler in an amount from about 0 to about 70% by weight, based on the total wet weight of the slurry, the additional first filler comprising a native or modified starch, maltodextrin, dextrose, calcium carbonate, a sugar alcohol, microcrystalline cellulose, or a combination thereof;   the first aerosol forming material in an amount from about 10 to about 20% by weight, based on the total wet weight of the slurry;   a cellulose ether in an amount from about 5 to about 15% by weight, based on the total wet weight of the slurry; and   water in an amount up to about 30% by weight, based on the total wet weight of the slurry.   
     
     
         47 . The method of  claim 46 , wherein the second substrate material in beaded form comprises:
 a tobacco or botanical material in an amount from about 20 to about 40% by weight, based on the total dry weight of the second substrate material;   an additional second filler in an amount from about 20 to about 40% by weight, based on the total dry weight of the second substrate material;   the second aerosol former in an amount from about 0 to about 20% by weight, based on the total dry weight of the second substrate material; and   a cellulose ether in an amount from about 0 to about 2% by weight, based on the total dry weight of the second substrate material.   
     
     
         48 . The method of  claim 46 , further comprising:
 (f) casting a layer of the slurry onto the composite substrate of (e), forming a wet layered composite substrate; and   (g) drying the wet layered composite substrate, forming a layered composite substrate with the second substrate material in beaded form embedded therein.