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

Abstract

The invention relates to substrates comprising an aerosol-generating material surrounded by a support, 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 surrounded by a support, 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 support comprises a sheet and the aerosol generating material is sandwiched between one or more of the sheets. 
     
     
         3 . A substrate as claimed in  claim 2 , wherein the sheet comprises one or more selected from the group consisting of: paper; card; paperboard; cardboard; 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. 
     
     
         4 . A substrate as claimed in  claim 2 , wherein the substrate has a rolled configuration. 
     
     
         5 . A substrate as claimed in  claim 1 , wherein the aerosol generating material is distributed within the support. 
     
     
         6 . A substrate as claimed in  claim 5 , wherein the support is a porous material with the aerosol-generating material distributed within the pores. 
     
     
         7 . A substrate as claimed in  claim 6 , wherein the support is a fibrous material. 
     
     
         8 . A substrate as claimed in  claim 7 , wherein the fibrous material is selected from the group consisting of: a fibrous tow; a non-woven sheet; a porous paper; and a fabric or fleece. 
     
     
         9 . A substrate as claimed in  claim 5 , wherein the support comprises an agglomerated material. 
     
     
         10 . A substrate as claimed in  claim 9 , wherein the substrate is an extruded mixture of the support and the aerosol-generating material. 
     
     
         11 . A substrate as claimed in  claim 9 , wherein the support comprises tobacco material. 
     
     
         12 . A substrate as claimed in  claim 1 , wherein the support comprises a heating material. 
     
     
         13 . 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. 
     
     
         14 . 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. 
     
     
         15 . A composition as claimed in  claim 14 , wherein the binder is selected from the group consisting of: thermoreversible gelling agents; starches; polysaccharides; pectins; celluloses; cellulose derivatives; and alginates. 
     
     
         16 . A substrate as claimed in  claim 1 , wherein the aerosol-generating material further comprises an aerosol-former material. 
     
     
         17 . 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. 
     
     
         18 . A substrate as claimed in  claim 1 , the precursor material comprising from about 1 to about 36 wt % aerosol-former material. 
     
     
         19 . A substrate as claimed in  claim 1 , the precursor material comprising from 0 to about 40% by weight of an excipient. 
     
     
         20 . 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. 
     
     
         21 . A substrate as claimed in  claim 1 , the aerosol-generating material comprising from about 1 to about 34% by weight aerosol-former material. 
     
     
         22 . A substrate as claimed in  claim 1 , the aerosol-generating material comprising from 0 to about 25% by weight of an excipient. 
     
     
         23 . 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. 
     
     
         24 . A substrate as claimed in  claim 1 , wherein the extract from a flavour- or active-containing plant material is an aqueous extract. 
     
     
         25 . A substrate as claimed in  claim 1 , wherein the extract from a flavour- or active-containing plant material is an aqueous tobacco extract. 
     
     
         26 . 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). 
     
     
         27 . A substrate as claimed in  claim 1 , comprising a moisture impermeable coating surrounding the aerosol-generating material. 
     
     
         28 . A substrate as claimed in  claim 1 , comprising a sorbent material. 
     
     
         29 . A substrate as claimed in  claim 1  for use in an aerosol provision system. 
     
     
         30 . An article comprising an aerosol-generating material surrounded by a support, the aerosol-generating material comprising a dried precursor material comprising an extract from a flavour- and/or active-containing plant material. 
     
     
         31 . An article comprising the substrate as claimed in  claim 1 . 
     
     
         32 . An article as claimed in  claim 30 , comprising a means to prevent or reduce the absorption of moisture by the dried aerosol-generating material. 
     
     
         33 . An article as claimed in  claim 32 , wherein the means is provided separately from the aerosol-generating material and/or substrate. 
     
     
         34 . An article as claimed in  claim 33 , wherein the means comprises a film or wrapper comprising a moisture impermeable coating or a sorbent or desiccant material. 
     
     
         35 . A non-combustible aerosol-provision system comprising a substrate as claimed in  claim 1 . 
     
     
         36 . A method for providing a substrate comprising:
 drying a precursor material comprising an extract from a flavour- and/or active-containing plant material and an aerosol-former material to form an aerosol-generating material; and   trapping the aerosol-generating material within a support.   
     
     
         37 . A method as claimed in  claim 36 , wherein the aerosol-generating material is sandwiched between two layers of support material. 
     
     
         38 . A method as claimed in  claim 37 , wherein the aerosol-generating material sandwiched between two layers of support material is rolled. 
     
     
         39 . A method as claimed in  claim 38 , wherein the aerosol-generating material is sandwiched between two layers of support material is rolled into the form of a hollow cylinder. 
     
     
         40 . A method as claimed in  claim 37 , wherein a binder is added to one or more of the aerosol-generating material and the support before the aerosol-generating material is sandwiched between the layers of support material. 
     
     
         41 . A method as claimed  claim 36 , wherein the aerosol-generating material is distributed within a fibrous support material. 
     
     
         42 . A method as claimed  claim 36 , comprising extruding a mixture of the aerosol-generating material and the support material. 
     
     
         43 . A method as claimed in  claim 36 , wherein the precursor material is dried by spray-drying or freeze-drying.