A substrate comprising an aerosol-generating material on a support and uses thereof

Abstract

The invention relates to substrates comprising an aerosol-generating material and a support comprising a rough and/or porous surface, the aerosol-generating material comprising a dried precursor material comprising an extract from a flavour- and/or active-containing plant material and optionally an aerosol-former material. The substrates may be used to generate an aerosol. For example, the substrates may be used in combustible or non-combustible aerosol-provision systems. The invention also relates to aerosol-provision systems comprising the substrates, and methods of providing a substrate.

1 . A substrate comprising an aerosol-generating material and a support comprising a rough and/or porous surface, the aerosol-generating material comprising a dried precursor material comprising an extract from a flavour- and/or active-containing plant material. 
     
     
         2 . A substrate as claimed in  claim 1 , wherein the aerosol-generating material is in the form of particles that adhere to pores or surface irregularities on the surface of the support. 
     
     
         3 . A substrate as claimed in  claim 2 , wherein the average diameter, width or dimension of the surface irregularities or pores on the surface of the support is at least about 10% greater than the average diameter, width or dimension of the particles of aerosol-generating material. 
     
     
         4 . A substrate as claimed in  claim 1 , wherein the support comprises one or more selected from the group consisting of: paper; card; paperboard; cardboard; a reconstituted material; a plastics material; a ceramic material; activated carbon; glass; a sintered material; a composite material; a plant-derived material; a fabric or fleece; a fibrous tow; a metal; and a metal alloy. 
     
     
         5 . A substrate as claimed in  claim 1 , wherein support comprises a heating material. 
     
     
         6 . A substrate as claimed in  claim 1 , wherein the aerosol-generating material covers at least a portion of a surface of the support. 
     
     
         7 . A substrate as claimed in  claim 1 , wherein a plurality of discrete portions or areas of the aerosol-generating material are provided on the support. 
     
     
         8 . A substrate as claimed in  claim 1 , wherein the substrate does not include a binder applied to adhere the aerosol-generating material to the support. 
     
     
         9 . A substrate as claimed in  claim 1 , wherein a binder is included to adhere the aerosol-generating material to the support, in an amount of from about 0.1 wt % to about 5 wt %, based on the entire weight of the aerosol-generating material. 
     
     
         10 . A composition as claimed in  claim 9 , wherein the binder is selected from the group consisting of: thermoreversible gelling agents; starches; polysaccharides; pectins; celluloses; cellulose derivatives; and alginates. 
     
     
         11 . A substrate as claimed in  claim 1 , wherein the aerosol-generating material comprises an aerosol-former material. 
     
     
         12 . A substrate as claimed in  claim 1 , the precursor material comprising from about 10 to about 95% by weight extract from a flavour- or active-containing plant material. 
     
     
         13 . A substrate as claimed in  claim 1 , the precursor material comprising from about 1 to about 36 wt % aerosol-former material. 
     
     
         14 . A substrate as claimed in  claim 1 , the precursor material comprising from 0 to about 40% by weight of an excipient. 
     
     
         15 . A substrate as claimed in  claim 1 , the aerosol-generating material comprising from about 45 to about 99% by weight dried extract from the flavour- or active-containing plant material. 
     
     
         16 . A substrate as claimed in  claim 1 , the aerosol-generating material comprising from about 1 to about 34% by weight aerosol-former material. 
     
     
         17 . A substrate as claimed in  claim 1 , the aerosol-generating material comprising from 0 to about 25% by weight of an excipient. 
     
     
         18 . A substrate as claimed in  claim 1 , wherein the plant material is selected from the group consisting of tobacco, eucalyptus, star anise, cocoa and hemp. 
     
     
         19 . A substrate as claimed in  claim 1 , wherein the extract from a flavour- or active-containing plant material is an aqueous extract. 
     
     
         20 . A substrate as claimed in  claim 1 , wherein the extract from a flavour- or active-containing plant material is an aqueous tobacco extract. 
     
     
         21 . A substrate as claimed in  claim 1 , the aerosol-generating material having a water content of no more than about 5% (calculated on a wet weight basis). 
     
     
         22 . A substrate as claimed in  claim 1 , comprising a moisture impermeable coating surrounding the aerosol-generating material. 
     
     
         23 . A substrate as claimed in  claim 1 , comprising a sorbent material. 
     
     
         24 . A substrate as claimed in  claim 1  for use in an aerosol provision system. 
     
     
         25 . An article comprising an aerosol-generating material and a support comprising a rough and/or porous surface, the aerosol-generating material comprising a dried precursor material comprising an extract from a flavour- and/or active-containing plant material. 
     
     
         26 . An article, comprising the substrate as claimed in  claim 1 . 
     
     
         27 . An article as claimed in  claim 25 , comprising a means to prevent or reduce the absorption of moisture by the dried aerosol-generating material. 
     
     
         28 . An article as claimed in  claim 27 , wherein the means is provided separately from the one or more agglomerates. 
     
     
         29 . An article as claimed in  claim 28 , wherein the means comprises a film or wrapper comprising a moisture impermeable coating or a sorbent or desiccant material. 
     
     
         30 . A non-combustible aerosol-provision system comprising a substrate as claimed in  claim 1 . 
     
     
         31 . A method for providing a substrate comprising drying a precursor material comprising an extract from a flavour- and/or active-containing plant material to form an aerosol-generating material, and depositing the dried aerosol-generating material on the rough and/or porous surface of a support. 
     
     
         32 . A method as claimed in  claim 31 , wherein the precursor material is dried by spray-drying or freeze-drying. 
     
     
         33 . A method as claimed in  claim 31 , wherein the particle size of the aerosol-generating material is adjusted prior to the material being deposited on the support. 
     
     
         34 . A method as claimed in a  claim 31 , wherein a binder is added to one or more of the aerosol-generating material and the support before the aerosol-generating material is deposited on the support. 
     
     
         35 . A method for providing a substrate comprising:
 applying a precursor material comprising an extract from a flavour- and/or active-containing plant material and an aerosol-former material to a rough surface of a support; and   drying the precursor material to form an aerosol generating material on the rough surface of the support.   
     
     
         36 . A method as claimed in  claim 31 , wherein the precursor material comprises an aerosol-former material. 
     
     
         37 . A method as claimed in  claim 31 , wherein a moisture-impermeable coating is applied to the aerosol-generating material.