RU2809573C2 - Aerosol generating substrate for use in element in form of aerosol source and element in form of aerosol source for use with aerosol delivery device - Google Patents

Abstract

FIELD: tobacco industry.

SUBSTANCE: group of inventions relates to aerosol generating substrate for use in an element in the form of an aerosol source and to an element in the form of an aerosol source for use with an aerosol delivery device. Aerosol generating substrate for use in the element in the form of the aerosol source contains fibrous filler material, aerosol forming material, and a set of heat-conducting components. The specified substrate is firstly formed in the form of a substrate sheet, and heat-conducting components are part of the specified substrate sheet. The substrate sheet is further cut to a set of pieces. A combination of mixed pieces of the specified set of pieces contains the specified substrate. Aerosol generating substrate for use in the element in the form of the aerosol source additionally contains an outer wrapping sheet made with the possibility of wrapping around substrate. The specified outer wrapping sheet includes a set of heat-conducting components containing a sequence of bands, formed on a surface of the outer wrapping sheet.

EFFECT: provision of a feeling of smoking cigarettes, cigars, or smoking pipes without burning substrate material, without the need for burning a heat source, and due to increased operational characteristics.

22 cl, 16 dwg

Description

TECHNICAL FIELD

[0001] The present invention relates to aerosol delivery products and their use for producing tobacco components or other materials in an inhalable form. More particularly, the present invention relates to support materials and aerosol source elements comprising support materials for aerosol delivery devices and systems, such as smoking articles, that use electrically generated heat to heat tobacco or non-tobacco material, preferably without significant combustion to provide an inhalable substance in aerosol form for human consumption.

BACKGROUND OF THE ART

[0002] Over the years, many smoking products have been proposed as an improvement or alternative to smoking products based on combustion of tobacco. Typical alternatives include devices that burn solid or liquid fuel to transfer heat to the tobacco, or that use a chemical reaction to provide such a heat source. Examples include smoking articles described in US Patent No. 9,078,473 to Worm et al., which is incorporated herein by reference in its entirety.

[0003] The rationale for improvements or alternatives to smoking articles has generally been to provide the experience associated with smoking cigarettes, cigars or pipes, but without delivering significant amounts of incomplete combustion and pyrolysis products. To this end, a variety of smoking products, flavor generators and medicinal inhalers have been proposed that use electrical energy to vaporize or heat volatile material or attempt to provide the sensation of smoking cigarettes, cigars or pipes without substantially burning the tobacco. See, for example, various alternative smoking articles, aerosol delivery devices, and heat generating sources disclosed in the prior art as described in US Pat. No. 7,726,320 to Robinson et al. and US Patent Application Publication No. 2013/0255702 by Griffith Jr. et al. and No. 2014/0096781 by Sears et al., which are incorporated herein by reference in their entirety. Also see, for example, the various types of smoking articles, aerosol delivery devices, and electrically powered heat generating sources referenced by trademark and trade information in US Patent Application Publication No. 2015/0220232 by Bless et al. , which is incorporated herein by reference in its entirety. Additional types of smoking articles, aerosol delivery devices, and electrically powered heat generating sources are referenced by trademark and commercial reference in U.S. Patent Application Publication No. 2015/0245659 by DePiano et al., which is also incorporated in its entirety. this document by reference. Other representative cigarettes or smoking articles that have been described and, in some cases, made commercially available include those described in US Pat. No. 4,735,217 to Gerth et al.; US patents No. 4,922,901, No. 4,947,874 and No. 4,947,875 by Brooks et al.; US Patent No. 5,060,671 by Counts et al.; US Patent No. 5,249,586 by Morgan et al.; US Patent No. 5,388,594 by Counts et al.; US Patent No. 5,666,977 by Higgins et al.; US Patent No. 6,053,176 by Adams et al.; US Patent No. 6,164,287 by White; US Patent No. 6,196,218 by Voges; US Patent No. 6,810,883 by Felter et al.; US Patent No. 6,854,461 by Nickols; US Patent No. 7,832,410 by Hon. US Patent No. 7,513,253 by Kobayashi; US Patent No. 7,726,320 by Robinson et al.; US Patent No. 7,896,006 by Hamano; US Patent No. 6,772,756 by Shayan; publication of US patent application No. 2009/0095311 by Hon; publications of US patent applications No. 2006/0196518, 2009/0126745 and 2009/0188490 by Hon; in US Patent Application Publication No. 2009/0272379 by Thorens et al.; in US Patent Application Publications No. 2009/0260641 and 2009/0260642 by Monsees et al.; in US Patent Application Publications No. 2008/0149118 and 2010/0024834 by Oglesby et al.; in US Patent Application Publication No. 2010/0307518 by Wang; in PCT publication of patent application WO 2010/091593 by Hon, which is incorporated herein by reference in its entirety.

[0004] Representative products that are similar in many attributes to traditional types of cigarettes, cigars or smoking pipes are commercially available as ACCORD® manufactured by Philip Morris Incorporated; ALPHA™, JOYE 510™ and M4™ manufactured by InnoVapor LLC; CIRRUS™ and FLING™, manufactured by White Cloud Cigarettes; BLU™, manufactured by Fontem Ventures B.V.; COHITA™, COLIBRI™, ELITE CLASSIC™, MAGNUM™, PHANTOM™ and SENSE™ manufactured by EPUFFER® International Inc.; DUOPRO™, STORM™ and VAPORKING® manufactured by Electronic Cigarettes, Inc.; EGAR™, manufactured by Egar Australia; eGo-C™ and eGo-T™ manufactured by Joyetech; ELUSION™, manufactured by Elusion UK Ltd; EONSMOKE®, manufactured by Eonsmoke LLC; FIN™TM, manufactured by FIN Branding Group, LLC; SMOKE® manufactured by Green Smoke Inc. USA; GREENARETTE™, manufactured by Greenarette LLC; HALLIGAN™, HENDU™, JET™, MAXXQ™, PINK™ and PITBULL™ manufactured by Smoke Stik®; HEATBAR™ manufactured by Philip Morris International, Inc.; HYDRO IMPERIAL™ and LXE™, manufactured by Crown7; LOGIC™ and THE CUBAN™, manufactured by LOGIC Technology; LUCI®, manufactured by Luciano Smokes Inc.; METRO®, manufactured by Nicotek, LLC; NJOY® and ONEJOY™ manufactured by Sottera, Inc.; NO. 7™ manufactured by SS Choice LLC; PREMIUM ELECTRONIC CIGARETTE™ manufactured by PremiumEstore LLC; RAPP E-MYSTICK™ manufactured by Ruyan America, Inc.; RED DRAGON™, manufactured by Red Dragon Products, LLC; RUYAN®, manufactured by Ruyan Group (Holdings) Ltd.; SF® manufactured by Smoker Friendly International, LLC; GREEN SMART SMOKER®, manufactured by The Smart Smoking Electronic Cigarette Company Ltd.; SMOKE ASSIST®, manufactured by Coastline Products LLC; SMOKING EVERYWHERE®, manufactured by Smoking Everywhere, Inc.; V2CIGS™ manufactured by VMR Products LLC; VAPOR NINE™, manufactured by VaporNine LLC; VAPOR4LIFE®, manufactured by Vapor 4 Life, Inc.; VEPPO™, manufactured by E-CigaretteDirect, LLC; VUSE®, manufactured by R.J. Reynolds Vapor Company; Mistic Menthol products manufactured by Mistic Ecigs; and the Vype product, manufactured by CN Creative Ltd. Other electrical aerosol delivery devices, and in particular devices that have been characterized as so-called electronic cigarettes, have been marketed under the trade names COOLER VISIONS™; DIRECT E-CIG™; DRAGONFLY™; EMIST™; EVERSMAKE™; GAMUCCI®; HYBRID FLAME™; KNIGHT STICKS™; ROYAL BLUES™; SMOKETIP®; SOUTH BEACH SMOKE™; IQOS™, manufactured by Philip Morris International and GLO™, manufactured by British American Tobacco.

[0005] Products that produce the taste and sensation of smoking by electrically heating tobacco, tobacco-derived materials, or other plant-derived materials have inadequate performance characteristics. For example, some products have an inappropriate release of fragrances or other respirable materials. Accordingly, it may be advantageous to provide a smoking article that can provide the sensation of smoking cigarettes, cigars or pipes without combustion of the support material, without the need for combustion of a heat source and at the expense of increased performance.

DISCLOSURE OF THE INVENTION

[0006] The present invention relates to aerosol generating substrates, aerosol source elements, methods for making an aerosol generating substrate, methods for producing an aerosol source element, and methods for forming an aerosol source element. The present invention includes, without limitation, the following example implementations.

[0007] Embodiment Example 1: An aerosol generating substrate for use in an aerosol source element, comprising a fibrous filler material, an aerosol generating material, and a plurality of thermally conductive components, wherein the substrate is formed as a sheet and the thermally conductive components are part of said sheet.

[0008] Implementation Example 2: The aerosol generating substrate of any preceding embodiment or any combination of any preceding embodiments, further comprising a binder material.

[0009] Implementation Example 3: The aerosol generating substrate of any prior embodiment or any combination of any prior embodiments, wherein thermally conductive components are included in the sheet.

[0010] Implementation Example 4: The aerosol generating substrate of any preceding embodiment or any combination of any preceding embodiments, wherein thermally conductive components are formed on the surface of the sheet.

[0011] Implementation Example 5: The aerosol generating substrate of any preceding embodiment or any combination of any preceding embodiments, wherein the form of the thermally conductive components comprises at least one of granular form, powder form, fibrous form, mesh form, and fibrous fabric form.

[0012] Implementation Example 6: The aerosol generating substrate of any preceding embodiment or any combination of any preceding embodiments, wherein the thermally conductive component material comprises at least one of a metallic material, a metal alloy material, a ceramic material, a carbon material, and a polymeric material. fibrous material coated with metallic material.

[0013] Implementation Example 7: The aerosol generating substrate of any preceding embodiment or any combination of any preceding embodiments, wherein the thermally conductive components are formed in a segmented pattern.

[0014] Implementation Example 8: The aerosol generating substrate of any preceding embodiment or any combination of any preceding embodiments, wherein the segmented pattern is created using at least one of printing, layering, stitching, and spot bonding.

[0015] Implementation Example 9: The aerosol generating substrate of any preceding embodiment or any combination of any preceding embodiments, wherein the plurality of thermally conductive components comprises at least one of a metal mesh layer material and a metal fiber fabric layer material.

[0016] Implementation Example 10: The aerosol generating substrate of any preceding embodiment or any combination of any preceding embodiments, wherein the fibrous filler material comprises at least one of tobacco material and tobacco-derived material.

[0017] Implementation Example 11: The aerosol generating substrate of any preceding embodiment or any combination of any preceding embodiments, wherein the fibrous filler material comprises a non-tobacco material.

[0018] Implementation Example 12: The aerosol generating substrate of any preceding embodiment or any combination of any preceding embodiments, wherein the segmented pattern is created using a masking pattern.

[0019] Embodiment Example 13: An aerosol source element for use with an aerosol delivery device, comprising a substrate portion comprising a fibrous filler material, an aerosol forming material, and a plurality of thermally conductive constituents, wherein the substrate portion is formed from a plurality of mixed pieces , cut from a base substrate sheet formed by a fibrous filler material, an aerosol-forming material, and a plurality of thermally conductive components, the thermally conductive components being included in said starting substrate sheet.

[0020] Implementation Example 14: The aerosol source element of any prior embodiment or any combination of any prior embodiments, wherein the substrate portion also contains a binder material.

[0021] Implementation Example 15: The aerosol source element of any preceding embodiment or any combination of any preceding embodiments, wherein the form of the thermally conductive constituents in the original backing sheet comprises at least one of the following: granular form, powder form, fibrous form , mesh form and fibrous fabric form.

[0022] Implementation Example 16: The aerosol source element of any preceding embodiment or any combination of any preceding embodiments, wherein the material of the thermally conductive constituents in the original substrate sheet comprises at least one of the following: metallic material, metal alloy material, ceramic material, carbon material and polymer fiber material coated with metal material.

[0023] Implementation Example 17: The aerosol source element of any preceding embodiment or any combination of any preceding embodiments, wherein the plurality of thermally conductive components comprise at least one of a metal mesh layered material and a fabric layered metallic material. fibers.

[0024] Implementation Example 18: The aerosol source element of any preceding embodiment or any combination of any preceding embodiments, wherein the fibrous filler material of the original backing sheet contains at least one of tobacco material and tobacco-derived material.

[0025] Implementation Example 19: The aerosol source element of any preceding embodiment or any combination of any preceding embodiments, wherein the fibrous filler material of the original backing sheet may comprise a non-tobacco material.

[0026] Embodiment Example 20: An aerosol source element for use with an aerosol delivery device, comprising a substrate portion comprising a fibrous filler material, an aerosol-forming material, and a plurality of thermally conductive constituents, the substrate portion being formed from a series of overlapping layers a base substrate sheet formed by a fibrous filler material, an aerosol-forming material, and a plurality of thermally conductive components, wherein the thermally conductive components are included in said base substrate sheet.

[0027] Implementation Example 21: The aerosol source element of any prior embodiment or any combination of any prior embodiments, wherein the substrate portion also contains a binder material.

[0028] Implementation Example 22: The aerosol source element of any preceding embodiment or any combination of any preceding embodiments, wherein the form of the thermally conductive constituents in the original backing sheet comprises at least one of the following: granular form, powder form, fibrous form , mesh form and fibrous fabric form.

[0029] Implementation Example 23: The aerosol source element of any preceding embodiment or any combination of any preceding embodiments, wherein the material of the thermally conductive constituents in the original substrate sheet comprises at least one of the following: metallic material, metal alloy material, ceramic material, carbon material and polymer fiber material coated with metal material.

[0030] Implementation Example 24: The aerosol source element of any preceding embodiment or any combination of any preceding embodiments, wherein the plurality of thermally conductive components comprise at least one of a metal mesh layered material and a fabric layered metallic material. fibers.

[0031] Implementation Example 25: The aerosol source element of any preceding embodiment or any combination of any preceding embodiments, wherein the fibrous filler material in the original backing sheet contains at least one of tobacco material and tobacco-derived material.

[0032] Implementation Example 26: The aerosol source element of any preceding embodiment or any combination of any preceding embodiments, wherein the fibrous filler material in the original backing sheet comprises a non-tobacco material.

[0033] Embodiment Example 27: An aerosol source element for use with an aerosol delivery device, comprising a wrapper portion and a substrate portion comprising a fibrous filler material, an aerosol generating material, and a plurality of thermally conductive components, the substrate portion is formed from a plurality of mixed pieces cut from a parent substrate sheet formed by a fibrous filler material, an aerosol-forming material, and a plurality of thermally conductive components, wherein the thermally conductive components are included in said original substrate sheet, and the wrapper portion comprises an outer wrapping sheet configured to wrapping around the part in the form of a substrate and containing a plurality of thermally conductive components.

[0034] Implementation Example 28: The aerosol source element of any prior embodiment or any combination of any prior embodiments, wherein the substrate portion also contains a binder material.

[0035] Implementation Example 29: The aerosol source element of any preceding embodiment or any combination of any preceding embodiments, wherein the form of the thermally conductive components of the outer wrapping sheet comprises at least one of the following: granular form, powder form, fibrous form, mesh form and fibrous fabric form.

[0036] Implementation Example 30: The aerosol source element of any preceding embodiment or any combination of any preceding embodiments, wherein the thermally conductive component material of the outer wrapping sheet comprises at least one of a metallic material, a metal alloy material, a ceramic material , carbon material and polymer fiber material coated with metal material.

[0037] Implementation Example 31: The aerosol source element of any preceding embodiment or any combination of any preceding embodiments, wherein the plurality of thermally conductive constituent substrate portions comprises at least one of a metal mesh layer material and a layers of fabric with metal fibers.

[0038] Implementation Example 32: The aerosol source element of any prior embodiment or any combination of any prior embodiments, wherein the fibrous filler material in the original backing sheet contains tobacco or tobacco-derived material.

[0039] Implementation Example 33: The aerosol source element of any prior embodiment or any combination of any prior embodiments, wherein the fibrous filler material in the original backing sheet comprises a non-tobacco material.

[0040] Implementation Example 34: An aerosol source element for use with an aerosol delivery device, comprising a wrapper portion and a substrate portion comprising a fibrous filler material, an aerosol forming material, and a plurality of thermally conductive components, the substrate portion formed from a series of overlapping layers of a sheet formed of a fibrous filler material, an aerosol-forming material, and a plurality of thermally conductive components, wherein the thermally conductive components are included in the sheet, and the wrapper portion comprises an outer wrap sheet configured to wrap around the backing portion and containing many heat-conducting components.

[0041] Implementation Example 35: The aerosol source element of any preceding embodiment or any combination of any preceding embodiments, wherein the substrate portion also contains a binder material.

[0042] Implementation Example 36: The aerosol source element of any preceding embodiment or any combination of any preceding embodiments, wherein the form of the thermally conductive components of the outer wrapping sheet comprises at least one of the following: granular form, powder form, fibrous form, mesh form and fibrous fabric form.

[0043] Implementation Example 37: The aerosol source element of any preceding embodiment or any combination of any preceding embodiments, wherein the outer wrap sheet thermally conductive component material comprises at least one of a metallic material, a metal alloy material, a ceramic material , carbon material and polymer fiber material coated with metal material.

[0044] Implementation Example 38: The aerosol source element of any prior embodiment or any combination of any prior embodiments, wherein the plurality of thermally conductive constituent substrate portions comprises at least one of a metal mesh layer material and a layers of fabric with metal fibers.

[0045] Implementation Example 39: The aerosol source element of any preceding embodiment or any combination of any preceding embodiments, wherein the fibrous filler material in the original backing sheet contains at least one of tobacco material and tobacco-derived material.

[0046] Embodiment Example 40: The aerosol source element of any prior embodiment or any combination of any prior embodiments, wherein the fibrous filler material in the original backing sheet comprises a non-tobacco material.

[0047] Embodiment Example 41: An aerosol source element for use with an induction heated aerosol delivery device comprising a resonant transmitter, wherein the aerosol source element comprises a substrate portion containing a fibrous filler material, an aerosol generating material, and a plurality of thermally conductive components, wherein the substrate portion is formed from a plurality of mixed pieces cut from the original substrate sheet formed by a fibrous filler material, an aerosol forming material, and a plurality of thermally conductive components, wherein the thermally conductive components are included in said original substrate sheet and comprise a resonant receiver, configured to indicate the presence of alternating current when exposed to an alternating magnetic field from a resonant transmitter.

[0048] Implementation Example 42: The aerosol source element of any prior embodiment or any combination of any prior embodiments, wherein the substrate portion also contains a binder material.

[0049] Implementation Example 43: The aerosol source element of any preceding embodiment or any combination of any preceding embodiments, wherein the form of the thermally conductive components comprises at least one of granular form, powder form, fibrous form, mesh form, and fibrous tissue form.

[0050] Implementation Example 44: The aerosol source element of any prior embodiment or any combination of any prior embodiments, wherein the thermally conductive component material comprises at least one of a metallic material, a metal alloy material, a ceramic material, a carbon material and a polymeric fibrous material coated with a metallic material.

[0051] Implementation Example 45: The aerosol source element of any preceding embodiment or any combination of any preceding embodiments, wherein the plurality of thermally conductive components comprise at least one of a metal mesh layered material and a fabric layered metallic material. fibers.

[0052] Embodiment Example 46: The aerosol source element of any prior embodiment or any combination of any prior embodiments, wherein the fibrous filler material comprises at least one of tobacco material and tobacco-derived material.

[0053] Implementation Example 47: The aerosol source element of any prior embodiment or any combination of any prior embodiments, wherein the fibrous filler material comprises a non-tobacco material.

[0054] Implementation Example 48: An aerosol source element for use with an induction heated aerosol delivery device comprising a resonant transmitter, wherein the aerosol source element comprises a substrate portion containing a fibrous filler material, an aerosol generating material, and a plurality of thermally conductive components, wherein the substrate portion is formed from a series of overlapping layers of a parent substrate sheet formed by a fibrous filler material, an aerosol forming material, and a plurality of thermally conductive components, wherein the thermally conductive components are included in said parent substrate sheet and comprise a resonant receiver configured to show the presence of alternating current when exposed to an alternating magnetic field from a resonant transmitter.

[0055] Implementation Example 49: The aerosol source element of any prior embodiment or any combination of any prior embodiments, wherein the substrate portion also contains a binder material.

[0056] Embodiment Example 50: The aerosol source element of any prior embodiment or any combination of any prior embodiments, wherein the form of the thermally conductive components comprises at least one of granular form, powder form, fibrous form, mesh form, and fibrous tissue form.

[0057] Implementation Example 51: The aerosol source element of any prior embodiment or any combination of any prior embodiments, wherein the thermally conductive component material comprises at least one of a metallic material, a metal alloy material, a ceramic material, a carbon material and a polymeric fibrous material coated with a metallic material.

[0058] Implementation Example 52: The aerosol source element of any preceding embodiment or any combination of any preceding embodiments, wherein the plurality of thermally conductive components comprise at least one of a metal mesh layered material and a fabric layered metallic material. fibers.

[0059] Embodiment Example 53: The aerosol source element of any prior embodiment or any combination of any prior embodiments, wherein the fibrous filler material of the original backing sheet contains at least one of tobacco material and tobacco-derived material.

[0060] Implementation Example 54: The aerosol source element of any prior embodiment or any combination of any prior embodiments, wherein the fibrous filler material in the original backing sheet comprises a non-tobacco material.

[0061] Implementation Example 55: An aerosol source element for use with an induction heated aerosol delivery device comprising a resonant transmitter, wherein the aerosol source element comprises a substrate portion containing a fibrous filler material, an aerosol generating material, and a plurality of thermally conductive components, wherein the substrate portion is formed from a plurality of granules formed by an extruded and spheronized mixture of a fibrous filler material, an aerosol forming material, and a plurality of thermally conductive components, wherein the plurality of thermally conductive components comprise a resonant receiver configured to indicate the presence of alternating current when exposed to an alternating magnetic field from a resonant transmitter is applied to it.

[0062] Implementation Example 56: The aerosol source element of any prior embodiment or any combination of any prior embodiments, wherein the substrate portion also contains a binder material.

[0063] Implementation Example 57: The aerosol source element of any preceding embodiment or any combination of any preceding embodiments, wherein the form of the thermally conductive components comprises at least one of granular form, powder form, fibrous form, mesh form, and fibrous tissue form.

[0064] Implementation Example 58: The aerosol source element of any preceding embodiment or any combination of any preceding embodiments, wherein the thermally conductive component material comprises at least one of a metallic material, a metal alloy material, a ceramic material, a carbon material and a polymeric fibrous material coated with a metallic material.

[0065] Implementation Example 59: The aerosol source element of any preceding embodiment or any combination of any preceding embodiments, wherein the plurality of thermally conductive components comprise at least one of a metal mesh layered material and a fabric layered metallic material. fibers.

[0066] Implementation Example 60: The aerosol source element of any preceding embodiment or any combination of any preceding embodiments, wherein the fibrous filler material comprises at least one of tobacco material and tobacco-derived material.

[0067] Implementation Example 61: The aerosol source element of any prior embodiment or any combination of any prior embodiments, wherein the fibrous filler material may comprise a non-tobacco material.

[0068] Implementation Example 62: A method of making an aerosol generating substrate for use in an aerosol source element, comprising providing a fibrous filler material, an aerosol-forming material, and a plurality of thermally conductive components, and forming a substrate sheet using the fibrous filler material, an aerosol-forming material. an aerosol, and a plurality of thermally conductive components, wherein the thermally conductive components are part of said support sheet.

[0069] Implementation Example 63: A method for manufacturing an aerosol generating substrate according to any preceding embodiment or any combination of any preceding embodiments, further comprising providing a binder material, wherein the step of forming a sheet of substrate also includes using the binder material.

[0070] Embodiment Example 64: A method for manufacturing an aerosol generating substrate according to any prior embodiment or any combination of any prior embodiments, wherein thermally conductive components can be incorporated into the substrate sheet.

[0071] Implementation Example 65: A method for manufacturing an aerosol generating substrate according to any preceding embodiment or any combination of any preceding embodiments, wherein thermally conductive components are formed on the surface of the substrate sheet.

[0072] Implementation Example 66: A method for manufacturing an aerosol generating substrate according to any prior embodiment or any combination of any prior embodiments, wherein the form of the thermally conductive components comprises at least one of granular form, powder form, fibrous form, mesh form, and fibrous tissue form.

[0073] Implementation Example 67: A method for manufacturing an aerosol generating substrate according to any preceding embodiment or any combination of any preceding embodiments, wherein the thermally conductive component material comprises at least one of a metal material, a metal alloy material, a ceramic material, a carbon material and a polymeric fibrous material coated with a metallic material.

[0074] Implementation Example 68: A method for manufacturing an aerosol generating substrate according to any preceding embodiment or any combination of any preceding embodiments, wherein the thermally conductive components are formed in a segmented pattern.

[0075] Implementation Example 69: A method for manufacturing an aerosol generating substrate according to any prior embodiment or any combination of any prior embodiments, wherein the segmented pattern is created using at least one of printing, layering, stitching, and spot bonding.

[0076] Implementation Example 70: A method for manufacturing an aerosol generating substrate according to any preceding embodiment or any combination of any preceding embodiments, wherein the plurality of thermally conductive components comprise at least one of a metal mesh layer material and a fabric layer material with metal fibers.

[0077] Implementation Example 71: A method for making an aerosol generating substrate according to any preceding embodiment or any combination of any preceding embodiments, wherein the fibrous filler material comprises at least one of tobacco material and tobacco-derived material.

[0078] Implementation Example 72: A method for making an aerosol generating substrate according to any prior embodiment or any combination of any prior embodiments, wherein the fibrous filler material comprises a non-tobacco material.

[0079] Implementation Example 73: A method for manufacturing an aerosol generating substrate according to any preceding embodiment or any combination of any preceding embodiments, wherein a segmented pattern is created using a masking pattern.

[0080] Implementation Example 74: A method of manufacturing an aerosol source element for use with an aerosol delivery device, comprising forming a base sheet of support comprising a fibrous filler material, an aerosol forming material, and a plurality of thermally conductive components, wherein the thermally conductive components are included in said parent sheet substrate, cutting the original substrate sheet into a plurality of pieces, forming a plurality of mixed pieces from said plurality of pieces of the original substrate sheet, and forming a substrate portion using said plurality of mixed pieces.

[0081] Implementation Example 75: A method of manufacturing an aerosol source element according to any preceding embodiment or any combination of any preceding embodiments, wherein the original backing sheet also contains a binder material.

[0082] Implementation Example 76: A method for manufacturing an aerosol source element according to any preceding embodiment or any combination of any preceding embodiments, wherein the form of the thermally conductive constituents in the original substrate sheet comprises at least one of the following: granular form, powder form, fibrous form, mesh form and fibrous fabric form.

[0083] Implementation Example 77: A method for manufacturing an aerosol source element according to any preceding embodiment or any combination of any preceding embodiments, wherein the thermally conductive constituent material in the original substrate sheet contains at least one of the following: a metal material, a metal alloy material , ceramic material, carbon material and polymer fiber material coated with metal material.

[0084] Implementation Example 78: A method of manufacturing an aerosol source element according to any preceding embodiment or any combination of any preceding embodiments, wherein the plurality of thermally conductive components comprise at least one of a metal mesh layer material and a fabric layer material. with metal fibers.

[0085] Implementation Example 79: A method for manufacturing an aerosol source element according to any preceding embodiment or any combination of any preceding embodiments, wherein the fibrous filler material of the original backing sheet contains at least one of tobacco material and tobacco-derived material .

[0086] Embodiment Example 80: A method for manufacturing an aerosol source element according to any prior embodiment or any combination of any prior embodiments, wherein the fibrous filler material of the original backing sheet comprises a non-tobacco material.

[0087] Implementation Example 81: A method of manufacturing an aerosol source element for use with an aerosol delivery device, comprising forming a base sheet of support comprising a fibrous filler material, an aerosol forming material, and a plurality of thermally conductive components, wherein the thermally conductive components are included in said parent sheet substrate, overlapping a plurality of layers of the original substrate sheet and forming a substrate-like portion using the overlapping layers.

[0088] Implementation Example 82: A method of manufacturing an aerosol source element according to any preceding embodiment or any combination of any preceding embodiments, wherein the original backing sheet also contains a binder material.

[0089] Implementation Example 83: A method for manufacturing an aerosol source element according to any preceding embodiment or any combination of any preceding embodiments, wherein the form of the thermally conductive constituents in the original substrate sheet comprises at least one of the following: granular form, powder form, fibrous form, mesh form and fibrous fabric form.

[0090] Implementation Example 84: A method for manufacturing an aerosol source element according to any preceding embodiment or any combination of any preceding embodiments, wherein the thermally conductive constituent material in the original substrate sheet contains at least one of the following: a metal material, a metal alloy material , ceramic material, carbon material and polymer fiber material coated with metal material.

[0091] Implementation Example 85: A method of manufacturing an aerosol source element according to any prior embodiment or any combination of any prior embodiments, wherein the plurality of thermally conductive components comprise at least one of a metal mesh layer material and a fabric layer material. with metal fibers.

[0092] Implementation Example 86: A method for manufacturing an aerosol source element according to any preceding embodiment or any combination of any preceding embodiments, wherein the fibrous filler material in the original backing sheet contains at least one of tobacco material and tobacco-derived material. material.

[0093] Implementation Example 87: A method for manufacturing an aerosol source element according to any prior embodiment or any combination of any prior embodiments, wherein the fibrous filler material in the original backing sheet comprises a non-tobacco material.

[0094] Implementation Example 88: A method of forming an aerosol source element for use with an aerosol delivery device, comprising forming a base sheet of support comprising a fibrous filler material, an aerosol forming material, and a plurality of thermally conductive components, wherein the thermally conductive components are included in said parent sheet substrate, cutting the original substrate sheet into a plurality of pieces, forming a plurality of mixed pieces from said plurality of pieces of the original substrate sheet, forming a substrate portion using said plurality of mixed pieces, and forming a wrapper portion, wherein the wrapper portion comprises an outer wrapping sheet, configured to be wrapped around the portion in the form of a substrate and containing a plurality of thermally conductive components.

[0095] Implementation Example 89: A method for forming an aerosol source element according to any preceding embodiment or any combination of any preceding embodiments, wherein the original backing sheet also contains a binder material.

[0096] Implementation Example 90: A method for forming an aerosol source element according to any preceding embodiment or any combination of any preceding embodiments, wherein the form of the thermally conductive components of the outer wrapping sheet comprises at least one of the following: granular form, powder form, fibrous shape, mesh shape and fibrous fabric shape.

[0097] Implementation Example 91: A method for forming an aerosol source element according to any preceding embodiment or any combination of any preceding embodiments, wherein the material of the thermally conductive components of the outer wrapping sheet contains at least one of the following: a metal material, a metal alloy material, ceramic material, carbon material and polymer fiber material coated with metal material.

[0098] Implementation Example 92: A method for forming an aerosol source element according to any preceding embodiment or any combination of any preceding embodiments, wherein the plurality of thermally conductive component substrate parts comprise at least one of the following: a metal mesh layer material and a material made from layers of fabric with metal fibers.

[0099] Implementation Example 93: A method for forming an aerosol source element according to any preceding embodiment or any combination of any preceding embodiments, wherein the fibrous filler material in the original backing sheet contains at least one of tobacco material and tobacco-derived material.

[0100] Implementation Example 94: A method for forming an aerosol source element according to any preceding embodiment or any combination of any preceding embodiments, wherein the fibrous filler material in the original backing sheet contains a non-tobacco material.

[0101] Implementation Example 95: A method of manufacturing an aerosol source element for use with an aerosol delivery device, comprising forming a base sheet of support comprising a fibrous filler material, an aerosol forming material, and a plurality of thermally conductive components, wherein the thermally conductive components are included in said parent sheet a substrate, overlapping a plurality of layers of the original substrate sheet, forming a substrate portion using the overlapping layers, and forming a wrap portion, the wrap portion comprising an outer wrap sheet configured to wrap around the substrate portion and containing a plurality of thermally conductive components.

[0102] Implementation Example 96: A method of manufacturing an aerosol source element according to any prior embodiment or any combination of any prior embodiments, wherein the original backing sheet also contains a binder material.

[0103] Implementation Example 97: A method for manufacturing an aerosol source element according to any preceding embodiment or any combination of any preceding embodiments, wherein the form of the thermally conductive components of the outer wrapping sheet comprises at least one of the following: granular form, powder form, fibrous shape, mesh shape and fibrous fabric shape.

[0104] Implementation Example 98: A method for manufacturing an aerosol source element according to any preceding embodiment or any combination of any preceding embodiments, wherein the material of the thermally conductive constituents of the outer wrapping sheet comprises at least one of the following: a metal material, a metal alloy material, ceramic material, carbon material and polymer fiber material coated with metal material.

[0105] Implementation Example 99: A method of manufacturing an aerosol source element according to any prior embodiment or any combination of any prior embodiments, wherein the plurality of thermally conductive components comprise at least one of a metal mesh layer material and a fabric layer material. with metal fibers.

[0106] Implementation Example 100: A method of manufacturing an aerosol source element according to any prior embodiment or any combination of any prior embodiments, wherein the fibrous filler material in the original backing sheet contains tobacco or tobacco-derived material.

[0107] Implementation Example 101: A method for manufacturing an aerosol source element according to any prior embodiment or any combination of any prior embodiments, wherein the fibrous filler material in the original backing sheet contains a non-tobacco material.

[0108] Implementation Example 102: A method of manufacturing an aerosol source element for use with an induction heated aerosol delivery device comprising a resonant transmitter, the method comprising forming a precursor sheet of substrate comprising a fibrous filler material, an aerosol generating material, and a plurality of thermally conductive materials. components, wherein the thermally conductive components are included in said original substrate sheet, cutting the original substrate sheet into a plurality of pieces, forming a plurality of mixed pieces from said plurality of pieces of the original substrate sheet, and forming a substrate portion using said plurality of mixed pieces, wherein the plurality of thermally conducting components comprise a resonant a receiver configured to indicate the presence of alternating current when exposed to an alternating magnetic field from a resonant transmitter.

[0109] Implementation Example 103: A method of manufacturing an aerosol source element according to any prior embodiment or any combination of any prior embodiments, wherein the original backing sheet also contains a binder material.

[0110] Implementation Example 104: A method of manufacturing an aerosol source element according to any prior embodiment or any combination of any prior embodiments, wherein the form of the thermally conductive components comprises at least one of the following: granular form, powder form, fibrous form, mesh form shape and fibrous fabric form.

[0111] Implementation Example 105: A method for manufacturing an aerosol source element according to any prior embodiment or any combination of any prior embodiments, wherein the thermally conductive component material comprises at least one of a metal material, a metal alloy material, a ceramic material, carbon material and polymer fiber material coated with metal material.

[0112] Implementation Example 106: A method of manufacturing an aerosol source element according to any prior embodiment or any combination of any prior embodiments, wherein the plurality of thermally conductive components comprise at least one of a metal mesh layer material and a fabric layer material. with metal fibers.

[0113] Implementation Example 107: A method of making an aerosol source element according to any prior embodiment or any combination of any prior embodiments, wherein the fibrous filler material comprises tobacco or tobacco-derived material.

[0114] Implementation Example 108: A method of making an aerosol source element according to any prior embodiment or any combination of any prior embodiments, wherein the fibrous filler material comprises a non-tobacco material.

[0115] Implementation Example 109: A method of manufacturing an aerosol source element for use with an induction heated aerosol delivery device comprising a resonant transmitter, the method comprising forming a precursor sheet of substrate containing a fibrous filler material, an aerosol generating material, and a plurality of thermally conductive materials. components, wherein the thermally conductive components are included in the specified original substrate sheet, overlapping a plurality of layers of the original substrate sheet and forming a part in the form of a substrate using the overlapping layers, wherein the plurality of thermally conductive components comprise a resonant receiver configured to indicate the presence of an alternating current when exposed to an alternating magnetic fields from a resonant transmitter.

[0116] Implementation Example 110: A method for manufacturing an aerosol source element according to any prior embodiment or any combination of any prior embodiments, wherein the original backing sheet also contains a binder material.

[0117] Implementation Example 111: A method of manufacturing an aerosol source element according to any prior embodiment or any combination of any prior embodiments, wherein the form of the thermally conductive components comprises at least one of the following: granular form, powder form, fibrous form, mesh form shape and fibrous fabric form.

[0118] Implementation Example 112: A method for manufacturing an aerosol source element according to any prior embodiment or any combination of any prior embodiments, wherein the thermally conductive component material comprises at least one of a metal material, a metal alloy material, a ceramic material, carbon material and polymer fiber material coated with metal material.

[0119] Implementation Example 113: A method of manufacturing an aerosol source element according to any prior embodiment or any combination of any prior embodiments, wherein the plurality of thermally conductive components comprise at least one of a metal mesh layer material and a fabric layer material with metal fibers.

[0120] Implementation Example 114: A method for manufacturing an aerosol source element according to any prior embodiment or any combination of any prior embodiments, wherein the fibrous filler material in the original backing sheet contains tobacco or tobacco-derived material.

[0121] Implementation Example 115: A method for manufacturing an aerosol source element according to any prior embodiment or any combination of any prior embodiments, wherein the fibrous filler material in the original backing sheet comprises a non-tobacco material.

[0122] Implementation Example 116: A method of making an aerosol source element for use with an induction heated aerosol delivery device comprising a resonant transmitter, the method comprising forming a mixture comprising a fibrous filler material, an aerosol generating material, and a plurality of thermally conductive constituents, extruding and spheronizing the mixture to produce a plurality of granules, forming a plurality of granules and forming a part in the form of a substrate using said plurality of granules, wherein the plurality of heat-conducting components comprise a resonant receiver configured to indicate the presence of alternating current when exposed to an alternating magnetic field from the resonant transmitter.

[0123] Implementation Example 117: A method of making an aerosol source element according to any prior embodiment or any combination of any prior embodiments, wherein the mixture also contains a binder material.

[0124] Implementation Example 118: A method of manufacturing an aerosol source element according to any prior embodiment or any combination of any prior embodiments, wherein the form of the thermally conductive components comprises at least one of the following: granular form, powder form, fibrous form, mesh form shape and fibrous fabric form.

[0125] Implementation Example 119: A method for manufacturing an aerosol source element according to any prior embodiment or any combination of any prior embodiments, wherein the thermally conductive component material comprises at least one of a metal material, a metal alloy material, a ceramic material, carbon material and polymer fiber material coated with metal material.

[0126] Implementation Example 120: A method for manufacturing an aerosol source element according to any prior embodiment or any combination of any prior embodiments, wherein the plurality of thermally conductive components comprise at least one of a metal mesh layer material and a fabric layer material. with metal fibers.

[0127] Implementation Example 121: A method of making an aerosol source element according to any prior embodiment or any combination of any prior embodiments, wherein the fibrous filler material comprises tobacco or tobacco-derived material.

[0128] Implementation Example 122: A method of making an aerosol source element according to any prior embodiment or any combination of any prior embodiments, wherein the fibrous filler material comprises a non-tobacco material.

[0129] These and other features, aspects and advantages of the disclosure of the present invention will become apparent upon reading the following detailed description taken in conjunction with the accompanying drawings, which are briefly described below.

BRIEF DESCRIPTION OF THE DRAWINGS

[0130] Thus, having described aspects of the present invention in the general terms set forth above, reference is made below to the accompanying drawings, which are not necessarily to scale, in which:

[0131] in FIG. 1 is a perspective view of an aerosol delivery device including a control body and an aerosol source member, the aerosol source member and the control body being connected to each other according to an embodiment of the disclosure of the present invention;

[0132] in FIG. 2 is a perspective view of the aerosol delivery device of FIG. 1, wherein the aerosol source element and the control body are disconnected from each other according to an example embodiment of the disclosure of the present invention;

[0133] in FIG. 3 is a perspective view of an aerosol source element according to an example embodiment of the present disclosure;

[0134] in FIG. 4 is a schematic view of a substrate sheet according to an example implementation of the disclosure of the present invention;

[0135] in FIG. 5 is a schematic view of a substrate sheet according to an example implementation of the disclosure of the present invention;

[0136] in FIG. 6 is a schematic diagram of an aerosol source element according to an example embodiment of the disclosure of the present invention;

[0137] in FIG. 7 is a schematic diagram of an aerosol source element according to an example embodiment of the disclosure of the present invention;

[0138] in FIG. 8 is a schematic diagram of an aerosol source element according to an example embodiment of the disclosure of the present invention;

[0139] in FIG. 9 is a schematic diagram of an aerosol source element according to an example embodiment of the disclosure of the present invention;

[0140] in FIG. 10 illustrates various steps of a method for manufacturing an aerosol generating substrate for use in an aerosol source element according to an example embodiment of the disclosure of the present invention;

[0141] in FIG. 11 illustrates various steps of a method for manufacturing an aerosol source element for use with an aerosol source delivery device according to an example embodiment of the disclosure of the present invention;

[0142] in FIG. 12 illustrates various steps of a method for manufacturing an aerosol source element for use with an aerosol source delivery device according to an example embodiment of the disclosure of the present invention;

[0143] in FIG. 13 illustrates various steps of a method for manufacturing an aerosol source element for use with an aerosol source delivery device according to an example embodiment of the disclosure of the present invention;

[0144] in FIG. 14 is a schematic view of a substrate sheet according to an example implementation of the disclosure of the present invention;

[0145] in FIG. 15 is a schematic diagram of an aerosol source element according to an example embodiment of the disclosure of the present invention; And

[0146] in FIG. 16 is a schematic diagram of an aerosol source element according to an example embodiment of the disclosure of the present invention.

IMPLEMENTATION OF THE INVENTION

[0147] The present invention is described in more detail below with reference to examples of its implementations. These exemplary embodiments are described in such a manner that the disclosure will thoroughly, completely and completely convey the scope of the invention to one skilled in the art. In fact, the present invention can be implemented in many different forms and should not be construed as limited to the embodiments given herein; rather, these embodiments are provided to ensure that the present invention complies with applicable legal requirements. In this specification and in the accompanying claims, grammatical construction indicating that an element is in the singular also implies the plural unless the context of the invention clearly dictates otherwise. In addition, while reference may be made herein to quantities, values, geometric relationships or the like, unless otherwise indicated, any one or more, if not all of them, may be absolute or approximate to account for acceptable variations that may occur, for example, due to technical tolerances or the like.

[0148] As described below, example implementations of the disclosure of the present invention relate to aerosol generating substrates for use in aerosol source elements and to aerosol source elements for use with aerosol delivery devices. Aerosol delivery devices according to the disclosure of the present invention use electrical energy to heat a material (preferably without burning the material to any significant extent) to produce an inhalable substance; and the components of such systems are in the form of products that are compact enough to be considered portable devices. In other words, the use of the components of the preferred aerosol delivery devices does not produce smoke in the sense that the aerosol arises primarily from by-products of combustion or pyrolysis of tobacco, but rather, the use of the preferred systems results in the formation of vapors generated by the evaporation or evaporation process of certain components included in them. In some exemplary embodiments, components of aerosol delivery devices may be characterized as electronic cigarettes, and said electronic cigarettes most preferably include tobacco and/or tobacco-derived components and thereby deliver tobacco-derived components in an aerosol form.

[0149] The aerosol-generating components of certain preferred aerosol delivery devices can provide a variety of sensations (e.g., inhalation and exhalation rituals, types of tastes and aromas, sensory effects, physical sensation, usage rituals, visual cues such as those provided by a visible aerosol, and the like) smoking a cigarette, cigar or pipe that involves lighting and burning tobacco (and then inhaling tobacco smoke) without any significant combustion of any of its components. For example, a user of an aerosol delivery device in accordance with some exemplary embodiments of the present disclosure may hold and use the component in the same manner as a smoker would use a traditional type of smoking article by inhaling through one end of said means to inhale the aerosol generated by the means, performing or performing puffs at selected intervals and the like.

[0150] While systems are generally described herein in terms of embodiments associated with aerosol delivery devices such as so-called “e-cigarettes” or “heating tobacco products,” it should be understood that the mechanisms, components, features, and methods can be implemented in many different forms and associated with different products. For example, the disclosure herein may be used in conjunction with embodiments of traditional smoking products (e.g., cigarettes, cigars, pipes, etc.), heated but non-burning cigarettes, and associated with packaging for any of the products disclosed herein. this document. Accordingly, it should be understood that the descriptions of the mechanisms, components, features and methods disclosed herein are in terms of embodiments related to aerosol delivery devices by way of example only and may be implemented and used in various other products and methods.

[0151] The proposed aerosol delivery devices may also be characterized as vapor-generating products or drug delivery products. Thus, such articles or devices may be adapted to deliver one or more substances (eg, flavoring agents and/or pharmaceutical active ingredients) in an inhalable form or state. For example, the inhaled substances may be essentially in the form of a vapor (eg, a substance that is in the gaseous phase at a temperature below its critical point). Alternatively, the inhaled substances may be in aerosol form (ie, a suspension of fine solid particles or liquid droplets in a gas). For the sake of simplicity, the term “aerosol” as used herein is intended to refer to vapors, gases and aerosols of a form or type suitable for human inhalation, whether or not visible and whether or not in a form that may be considered "smoke-like". The physical form of the respirable substance is not necessarily limited by the nature of the devices of the invention, but rather may depend on the nature of the substance and the respirable substance itself as to whether the substance is in a vapor state or an aerosol state. In some implementations, the terms may be used interchangeably. Thus, for simplicity, the terms used to describe aspects of this invention should be understood as interchangeable unless otherwise noted.

[0152] Aerosol delivery devices according to the disclosure of the present invention generally comprise a number of components located within an outer housing or shell, which may be referred to as a housing. The overall design of the outer housing or shell may vary, and the configuration and format of the outer housing, which may define the overall size and shape of the aerosol delivery device, may also vary. Typically, an elongated body resembling the shape of a cigarette or cigar may be formed from one single housing, or the elongated housing may be formed from two or more separable housings. For example, an aerosol delivery device may comprise an oblong casing or body that may be substantially tubular in shape and thus resemble the shape of a conventional cigarette or cigar. In one example, all components of the aerosol delivery device are located in a single housing. Alternatively, the aerosol delivery device may comprise two or more housings that are connected and removable. For example, an aerosol delivery device may have at one end a control housing comprising a housing containing one or more reusable components (e.g., a battery such as a rechargeable battery and/or a rechargeable supercapacitor, and various electronic equipment for controlling the operation of the product), and at at the other end, a removably attached outer housing or shell containing a disposable portion (for example, a disposable cartridge containing a flavor). More specific formats, configurations and arrangements of components located within single housing type units or within a releasably multi-part housing type unit will be apparent in light of the further disclosure of the invention presented below. In addition, the configuration of various aerosol delivery devices and the arrangement of components can be understood by considering commercially available electronic aerosol delivery devices.

[0153] As will be described in more detail below, aerosol delivery devices according to the disclosure of the present invention include some combination of a power source (e.g., an electrical power supply), at least one control component (e.g., means for actuating, controlling, regulating, and stopping power to generate heat, for example, by controlling the flow of electrical current from the power source to other components of the product, for example, a microprocessor, separate or as part of a microcontroller), a heater or heat generating element (for example, an electrical resistive heating element or other component, and/or an inductive coil or other suitable components and/or one or more radiant heating elements) and an aerosol source element that contains a support portion capable of generating an aerosol upon application of sufficient heat. In various embodiments, the aerosol source element may include a mouthpiece end or tip configured to allow puffing through the aerosol delivery device to inhale the aerosol (e.g., providing a predetermined path for air flow through the article so that the generated aerosol can be discharged from it after tightening).

[0154] In various embodiments of the proposed aerosol delivery device, the alignment of the components may be different. In some embodiments, the support material may be positioned adjacent to the heating element so as to enhance delivery of the aerosol to the user. However, other configurations are not excluded. In general, the heating element may be located sufficiently close to the support material such that heat from the heating element can vaporize the support material (and in some embodiments, one or more flavorings, medications, etc., which may also be provided for delivery to the user ) and form an aerosol for delivery to the user. When the heating element heats the substrate material, an aerosol is formed, released or generated in a physical form suitable for inhalation by the consumer. It should be noted that the above terms should be considered interchangeable, so that forms of the above term such as "release", "release", "releases" or "released" include forms such as "form" or "generate", "forming" or "generating", "forming" or "generating" and "formed" or "generated". In particular, the inhalable substance is released in the form of a vapor or aerosol or a mixture thereof, which conditions are also used interchangeably herein unless otherwise indicated.

[0155] As discussed above, various embodiments of the aerosol delivery device may include a battery and/or other electrical power source to provide sufficient electrical current to provide various functions of the aerosol delivery device, such as powering a heating element, powering control systems, powering indicators, and the like. similar. As will be described in more detail below, the power supply may have various embodiments. Preferably, the power source may be configured to supply sufficient energy to quickly activate the heating element to form an aerosol and supply energy to the aerosol delivery device for use for the required period of time. The power source is preferably sized to fit comfortably into the aerosol delivery device so that the aerosol delivery device can be conveniently used. Examples of suitable power sources include lithium ion batteries, which are preferably rechargeable (eg, a rechargeable lithium manganese dioxide battery). In particular, lithium polymer batteries can be used since such batteries can provide increased safety. Other types of batteries can also be used - for example, N50-AAA CADNICA nickel-cadmium cells. In addition, the preferred power source is lightweight enough to not interfere with the desired smoking process. Some examples of possible power supplies are described in U.S. Patent No. 9,484,155 to Peckerar et al. and U.S. Patent Application Publication No. 2017/0112191 to Sur et al., filed Oct. 21, 2015, the disclosures of which are incorporated herein by reference in its completeness.

[0156] In additional embodiments, the power supply may also include a capacitor. Capacitors can discharge faster than batteries and can be charged between puffs, allowing the battery to discharge into the capacitor at a lower rate than if it were used to directly power the heating element. For example, a supercapacitor—such as an electrical double-layer capacitor (EDLC)—can be used alone or in combination with a battery. When used separately, the supercapacitor can be charged before each use of the product. Thus, the device may also include a charger component that can be attached to the smoking article between uses to replenish the supercapacitor.

[0157] Additional components may be used in the proposed aerosol delivery device. For example, an aerosol delivery device may include a flow sensor that is sensitive to either changes in pressure or changes in air flow when a user takes a puff through the product (eg, a puff actuated switch). Other possible current on/off mechanisms may include a temperature actuated on/off switch or a lip pressure actuated switch). An example of a mechanism that can provide such pinch actuation capability includes the Model 163PC01D36 silicon sensor manufactured by the MicroSwitch Division of Honeywell, Inc., Freeport, Illinois. Representative flow sensors, electrical current control components, and other electrical current control components, including various microcontrollers, sensors, and switches for aerosol delivery devices, are described in US Pat. No. 4,735,217 to Gerth et al.; No. 4,922,901, No. 4,947,874 and No. 4,947,875 by Brooks et al.; No. 5,372,148 by McCafferty et al.; No. 6,040,560 by Fleischhauer et al.; No. 7,040,314 by Nguyen et al.; No. 8,205,622 by Pan, all of which are incorporated herein by reference in their entirety. Reference is also made to the control circuits described in US Patent No. 9,423,152 to Ampolini et al., which is incorporated herein by reference in its entirety.

[0158] In another example, a personal vaporizer unit may include a first conductive surface configured to contact a first body part of a user holding the personal vaporizer unit, and a second conductive surface electrically insulated from the first conductive surface configured to contact a second body part user. Thus, when the personal vaporizer unit senses a change in conductivity between the first conductive surface and the second conductive surface, the vaporizer is activated to vaporize the substance so that the vapor can be inhaled by the user holding the unit. The first body part and the second body part may be a lip or parts of the arm(s). The two conductive surfaces can also be used to charge the battery contained in the personal vaporizer unit. The two conductive surfaces may also form or be part of a connector that may be used to output data stored in memory. Reference is also made to US Patent No. 9,861,773 to Terry et al., which is incorporated herein by reference in its entirety.

[0159] In addition, US Pat. No. 5,154,192 to Sprinkel et al. discloses indicators for smoking articles; US Patent No. 5,261,424 by Sprinkel Jr. discloses piezoelectric sensors that can be provided on the oral end of the device to detect the user's lip activity associated with the execution of a puff, followed by heating; US Pat. No. 5,372,148 to McCafferty et al. discloses a tightening sensor for controlling the flow of energy in a thermal load array in response to the tightening resistance of a mouthpiece; US Pat. No. 5,967,148 to Harris et al. discloses receptacles in a smoking device that include an identifier that detects a discontinuity in the infrared transmittance value of an inserted component and a controller that executes a detection program when the component is inserted into the receptacle; US Pat. No. 6,040,560 to Fleischhauer et al. describes a specific executable power cycle with multiple differential phases; US Patent No. 5,934,289 by Watkins et al discloses photonic-optocoupler components; U.S. Patent No. 5,954,979 to Counts et al. discloses means for varying draw resistance through a smoking device; US Patent No. 6,803,545 to Blake et al. discloses certain battery configurations for use in smoking devices; US Pat. No. 7,293,565 to Griffen et al. discloses various charging systems for use with smoking devices; U.S. Patent No. 8,402,976 to Fernando et al. discloses computer communications for smoking devices designed to facilitate charging and allow automated control of the device; US Pat. No. 8,689,804 to Fernando et al. discloses identification systems for smoking devices; and PCT patent application publication WO 2010/003480 by Flick discloses a fluid flow detection system indicating the presence of a puff in an aerosol generation system; and the contents of all of the above inventions are fully incorporated into this application by reference.

[0160] Further examples of components associated with electronic aerosol delivery products and disclosing materials and components that can be used in the present device are described in US Pat. No. 4,735,217 to Gerth et al.; No. 5,249,586 by Morgan et al.; No. 5,666,977 by Higgins et al.; No. 6,053,176 by Adams et al.; No. 6,164,287 by White; No. 6,196,218 by Voges; No. 6,810,883 by Felter et al.; #6,854,461 by Nickols; No. 7,832,410 by Hon; #7,513,253 by Kobayashi; No. 7,896,006 by Hamano; No. 6,772,756 by Shayan; No. 8,156,944 and No. 8,375,957 by Hon; No. 8,794,231 by Thorens et al.; No. 8,851,083 by Oglesby et al.; No. 8,915,254 and 8,925,555 by Monsees et al.; No. 9,220,302 by DePiano et al.; publications of US patent applications No. 2006/0196518 and No. 2009/0188490 by Hon; publication of US patent application No. 2010/0024834 by Oglesby et al.; US Patent Application Publication No. 2010/0307518 by Wang; publication of patent application PCT WO 2010/091593 by Hon and publication of patent application PCT WO 2013/089551 by Foo, which are incorporated herein by reference in their entirety. Additionally, US Patent Application Publication No. 2017/0099877 by Worm et al., filed October 13, 2015, discloses capsules that can be included in aerosol delivery devices, and configurations for key fob-shaped aerosol delivery devices, and is fully included incorporated into this document by reference. The various materials disclosed in the foregoing documents may be incorporated into the present devices in various embodiments, and all of the foregoing disclosures are incorporated herein by reference in their entirety.

[0161] More specific formats, configurations and arrangements of various support materials, aerosol source elements and components in aerosol delivery devices in accordance with the present invention will be apparent in light of the further disclosure of the invention presented below. In addition, the selection of various components of aerosol delivery devices can be understood by considering commercially available electronic aerosol delivery devices. Further, the arrangement of components within the aerosol delivery device can also be assessed by considering commercially available electronic aerosol delivery devices.

[0162] In this regard, in FIG. 1 shows an aerosol delivery device 100 according to an example implementation of the disclosure of the present invention. The aerosol delivery device 100 may include a control housing 102 and an aerosol source element 104. In various embodiments, the aerosol source element 104 and the control housing 102 may be aligned for permanent or detachable operation. In this regard, FIG. 1 shows the aerosol delivery device 100 in a connected configuration, and FIG. 2 shows the aerosol delivery device 100 in a disconnected configuration. Various mechanisms may connect the aerosol source element 104 and the control housing 102, for example, in the form of a threaded coupling, a press-fit coupling, an interference fit, a sliding fit, a magnetic coupling, and the like.

[0163] In various embodiments, the aerosol delivery device 100 according to the disclosure of the present invention may take various general shapes, including, without limitation, a general shape that may be defined as a substantially rod-shaped or substantially tubular shape or a substantially cylindrical shape. In the embodiments of FIGS. 1-3, device 100 has a substantially circular cross-section, however, other cross-sectional shapes (eg, oval, square, triangle, etc.) are also covered by the disclosure of the present invention. Such language, which describes the physical form of the product, can also be applied to its individual components, including the control element 102 and the aerosol source element 104. In other embodiments, the control housing may take another portable shape, such as a small box shape.

[0164] In specific embodiments, the control housing 102 and/or the aerosol source element 104 may be referred to as disposable or reusable. For example, the control housing 102 may have a replaceable battery or a rechargeable battery, a solid state battery, a thin film solid state battery, a rechargeable supercapacitor, and the like, and thus be combined with any type of recharging technology, including connection to a conventional wall charger, connection to a car charger (e.g. cigarette lighter socket), connection to a computer, e.g. via a cable or universal serial bus (USB) connector (e.g. USB 2.0, 3.0, 3.1, USB Type C), connection to a photovoltaic cell (sometimes listed as solar photovoltaic cell ) or to a solar PV panel, to a wireless charger such as a charger that uses inductive wireless charging (including, for example, wireless charging in accordance with the Qi wireless charging standard developed by the Wireless Power Consortium (WPC)) or wireless radio frequency (RF) charger. Examples of inductive wireless charging systems are described in US Patent Application Publication No. 2017/0112196 by Sur et al., which is incorporated herein by reference in its entirety. Additionally, in some embodiments, the aerosol source element 104 may comprise a disposable device. A disposable component for use with a control housing is disclosed in US Pat. No. 8,910,639 to Chang et al., which is incorporated herein by reference in its entirety.

[0165] In the illustrated embodiment, aerosol source element 104 includes a heated end 106 that is insertable into control housing 102 and a mouthpiece end 108 upon which a user draws to create an aerosol. At least a portion of the heated end 106 may include a substrate portion 110. As described in more detail below, in some embodiments, the substrate portion 110 may comprise non-tobacco material, tobacco material, tobacco-containing pellets, tobacco pieces, tobacco strips, reconstituted tobacco material, or combinations thereof, and/or a mixture of finely ground tobacco, spray-dried tobacco extract extract or other form of tobacco mixed with optional inorganic materials (such as calcium carbonate), optional flavoring agents and aerosol forming materials to form a substantially solid or semi-solid support. Representative types and compositions of solid and semi-solid structures are disclosed in US Patent No. 8,424,538 to Thomas et al., US Patent No. 8,464,726 to Sebastian et al., US Patent Application Publication No. 2015/0083150 to Conner et al., in US Patent Application Publication No. 2015/0157052 by Ademe et al., and US Patent Application Publication No. 2017-0000188 by Nordskog et al., filed June 30, 2015, all of which are incorporated herein in their entirety by links. Other examples of substrates are described in US Patent Application Publication No. 2013/0255702 to Griffith et al., the disclosure of which is incorporated herein by reference in its entirety.

[0166] In various embodiments, the aerosol source element 104, or a portion thereof, may be wrapped in an outer wrapping material 112 (see FIG. 3). In various embodiments, the mouthpiece end 108 of the aerosol source element 104 may include a filter 114, which, for example, may be made of cellulose acetate or propylene material. The filter 114 may additionally or alternatively contain strands of tobacco-containing tobacco, as described in US Patent No. 5,025,814 to Raker et al., which is incorporated herein by reference in its entirety. In various embodiments, the filter 114 may increase the structural integrity of the mouth end of the aerosol source element and/or provide filtration capacity, if desired, and/or provide draw resistance. The outer wrapping material may comprise a material that resists heat transfer, which may comprise paper or other fibrous material such as cellulose material. The outer wrap material may also include at least one filler material embedded in or dispersed within the fibrous material. In various embodiments, the filler material may be in the form of water-insoluble particles. Additionally, the filler material may include inorganic components. In various embodiments, the outer wrapper material may be formed from a plurality of layers, such as an underlying layer, a base layer, and an overlying layer, such as a typical wrapping paper in a cigarette. Such materials may include, for example, lightweight rag fibers such as flax, hemp, sisal, rice stalks and/or esparto. The outer wrap may also include a material commonly used in a conventional cigarette filter element, such as cellulose acetate. In addition, the excess length of the outer wrap at the mouthpiece end 108 of the aerosol source element may serve simply to separate the substrate portion 110 from the consumer's mouth or to provide space for housing filter material, as described below, or to influence the puffing effect of the aerosol source element. product, or the characteristics of the flow of vapor or aerosol leaving the device during a puff. Further discussion regarding outer wrap material configurations that may be used with the present invention can be found in US Pat. No. 9,078,473 to Worm et al., which is incorporated herein by reference in its entirety.

[0167] In various embodiments, other components may exist between the substrate portion 110 and the mouthpiece end 108 of the aerosol source element 104, and the mouthpiece 108 may include a filter 114. For example, in some embodiments, between the substrate portion 110 and one or any combination of the following may be located at the mouth end 108 of the aerosol source element 104: an air gap; hollow tubular structure; phase change materials for air cooling; aroma release agent; ion exchange fibers capable of selective chemical adsorption; airgel particles as a filter medium and other suitable materials.

[0168] As will be described in more detail below, the present invention is intended for use with a conductive and/or inductive heating source to heat a substrate material to form an aerosol. In various embodiments, the conductive heating source may include a heating assembly that includes a resistive heating element. Resistive heating elements may be configured to generate heat when electrical current is passed through them. Electrically conductive materials used as resistive heating elements may have low mass, low density and moderate resistivity and are thermally stable at temperatures encountered during use. The useful heating elements heat up and cool down quickly and thus ensure efficient use of energy. Rapid heating of the element may be beneficial to ensure almost immediate vaporization of aerosol precursor material in its immediate vicinity. Rapid cooling prevents significant evaporation (and therefore consumption) of aerosol precursor material during periods when aerosol formation is not desired. Such heating elements can also provide relatively precise control of the temperature range over which the aerosol precursor material is located, especially when using time-dependent current control. Suitable electrically conductive materials are preferably inactive with respect to materials being heated (eg, aerosol precursor materials and other respirable materials) so as not to adversely affect the aroma or content of the resulting aerosol or vapor. Non-limiting examples of materials that can be used as an electrically conductive material include carbon, graphite, carbon/graphite composites, metals, ceramics such as metal and non-metal carbides, nitrides, oxides, silicides, intermetallic compounds, cermets, metal alloys and metal foil. In particular, fire-resistant materials may be suitable. Different materials can be mixed to achieve the desired properties of resistivity, mass and thermal conductivity. In specific embodiments, metals that may be used include, for example, nickel, chromium, nickel-chromium alloys (eg, nichrome), and steel. Materials that may be suitable for providing resistance heating are described in US Pat. No. 5,060,671 to Counts et al.; No. 5,093,894 by Deevi et al.; No. 5,224,498 by Deevi et al.; #5,228,460 by Sprinkel Jr. and etc.; No. 5,322,075 by Deevi et al.; No. 5,353,813 by Deevi et al.; No. 5,468,936 by Deevi et al.; No. 5,498,850 by Das; No. 5,659,656 by Das; No. 5,498,855 by Deevi et al.; No. 5,530,225 by Hajaligol; No. 5,665,262 by Hajaligol; No. 5,573,692 by Das et al.; and No. 5,591,368 by Fleischhauer et al., the disclosures of which are incorporated herein by reference in their entirety.

[0169] In various embodiments, the heating element can be made in various forms, for example, in the form of foil, foam, mesh, hollow sphere, hemisphere, disks, spirals, fibers, wires, films, threads, strips, tapes or cylinders. Such heating elements often contain metallic material and are configured to generate heat as a result of electrical resistance associated with the passage of electric current through them. Such resistive heating elements may be located adjacent to and/or in direct contact with the substrate portion. The heating assembly or heating element may be located in the control housing and/or aerosol source element, as will be described in more detail below. In various embodiments, the substrate portion may include components (i.e., thermally conductive components) that are incorporated into or are a part of the substrate portion, wherein the substrate portion may serve as or assist in the operation of a heating assembly. Some examples of various heating elements or components are described in US Pat. No. 9,078,473 to Worm et al., the disclosure of which is incorporated herein by reference in its entirety.

[0170] Some non-limiting examples of various heating element configurations include configurations in which the heating element or component is located proximate to the aerosol source element. For example, in some examples, at least a portion of the heating element may surround at least a portion of the element as an aerosol source. In other examples, one or more heating elements may be located adjacent the exterior of the element to provide an aerosol source when inserted into the control housing. In other examples, at least a portion of the heating element may penetrate at least a portion of the aerosol source element (such as, for example, one or more pins and/or needles that penetrate the aerosol source element) upon insertion of the aerosol source element. aerosol source into the control housing.

[0171] In various embodiments, the heating element can take a variety of forms. For example, in one embodiment, the heating element may include a cylinder or other heating device located in the control housing 102. In various embodiments, the heating element may be made of one or more conductive materials, including, but not limited to, copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, carbon (such as graphite) or any combination thereof. In various embodiments, the heating element may also be coated with any of these or other conductive materials. The heating element may be located proximate the interacting end of the control housing 102 and may be configured to substantially surround a portion of the heated end 106 of the aerosol source element 104, which includes a substrate portion 110. Thus, the heating element may be positioned proximate the substrate portion 110 of the aerosol source element 104 when the aerosol source element is inserted into the control housing 102.

[0172] As will be described in more detail below, in various embodiments, one or more thermally conductive components may be located within the substrate and/or on its surface. Although in some embodiments the substrate may comprise a sheet, in other embodiments the substrate may have a variety of different shapes. In various embodiments, the substrate may be used to create a substrate portion of the aerosol source element. Thus, in various embodiments, as the heating element heats up, the thermally conductive components increase thermal conductivity within the substrate portion. Although in some embodiments the heating element may comprise a cylinder, it should be noted that in other embodiments the heating element may take various shapes and, in some embodiments, may directly contact and/or penetrate the substrate portion.

[0173] As described above, in addition to being capable of being configured for use with conductive heating sources, the present invention may also be configured for use with an inductive heating source to heat a substrate portion to form an aerosol. In various embodiments, the inductive heating source may include a resonant transformer, which may include a resonant transmitter and a resonant receiver (eg, a susceptor). In some embodiments, the resonant transmitter may be located in the control housing 102, and the substrate portion may include thermally conductive components that contain the resonant receiver. In other embodiments, the thermally conductive components may contribute to the operation of a separate resonant receiver or may provide an additional resonant receiver.

[0174] For example, in some embodiments, the control housing 102 may include a resonant transmitter, which, for example, may include a foil material, coil, cylinder, or other structure configured to generate an alternating magnetic field. In some embodiments, the thermally conductive substrate component portions may include a resonant receiver such that an alternating current is induced in the thermally conductive substrate component portions. In other embodiments, the thermally conductive component portions in the form of a substrate may facilitate the operation of a separate resonant receiver, or may serve as a second resonant receiver such that an alternating current is induced in the thermally conductive components in addition to the separate resonant receiver, which in some embodiments may be located in control housing 102. For example, in various embodiments, a resonant receiver located in control housing 102 may include one or more pins that extend into or are surrounded by a substrate portion. Other possible resonant transformer components, including resonant transmitters and resonant receivers, are described in US Patent Application No. 15/799,365, filed October 31, 2017, which is incorporated herein by reference in its entirety.

[0175] In other embodiments, the resonant transmitter may comprise a helical coil configured to define a cavity in which the aerosol source element and, in particular, a substrate portion of the aerosol source element is located. In some embodiments, the helical coil may be located between the outer wall of the device and the receiving cavity. In one embodiment, the coil windings may have a circular cross-sectional shape, however, in other embodiments, the coil windings may have a variety of other cross-sectional shapes, including, but not limited to, oval, rectangular, L-shaped, T-shaped, triangular, and combinations thereof . In another embodiment, the rod may extend into a portion of the receiving cavity, and the rod may include a resonant transmitter, for example, by providing a coil structure around or within the rod. In various embodiments, the aerosol source element may be located in a receiving cavity in which one or more components of the aerosol source element may serve as a resonant receiver. For example, in some embodiments, the thermally conductive substrate constituent parts may include a resonant receiver. In other embodiments, the thermally conductive components may contribute to the operation of a separate resonant receiver (such as, for example, a rod, rod and/or receiver particles) that is located in the aerosol source element. As noted above, in various embodiments of the present invention, the aerosol source element may comprise a substrate portion that contains a substrate material. In various embodiments, the backing material may comprise a backing sheet. In FIG. 4 is a schematic view of a substrate sheet 200 according to an example implementation of the disclosure of the present invention. In particular, in FIG. 4 shows a cast substrate sheet 200 containing an aerosol generating substrate. In the specific embodiment shown in FIG. 4, the substrate sheet 200 contains a mixture of fibrous filler material, an aerosol-forming material, a binder material, and a plurality of thermally conductive constituents. In some embodiments, the fibrous filler material may comprise a plant-derived non-tobacco material, such as cellulose pulp material. In other embodiments, the non-tobacco filler material may not be a plant-derived material.

[0176] In various embodiments, tobacco materials that may be useful in the present invention may vary and may include, for example, fire-cured tobacco, Barley tobacco, Eastern tobacco, Maryland tobacco, dark tobacco, dark fire-cured tobacco, and shag, as well as other rare or specialty tobaccos or mixtures thereof. Tobacco materials may also include so-called "mixed" forms and processed forms, such as processed tobacco stems (e.g., cut rolled or cut puffed stems), expanded tobacco (e.g., puffed tobacco such as dry ice expanded tobacco, DIET), preferably in the form of cut filler), reconstituted tobaccos (for example, reconstituted tobaccos produced using paper or cast sheet manufacturing processes). Various representative tobacco types, processed tobacco types, and tobacco blend types are set forth in U.S. Patent No. 4,836,224 to Lawson et al.; in US patent No. 4,924,888 by Perfetti et al.; in US patent No. 5,056,537 by Brown et al.; in US patent No. 5,159,942 by Brinkley et al.; in US Patent No. 5,220,930 by Gentry; in US patent No. 5,360,023 by Blakley et al.; in US patent No. 6,701,936 by Shafer et al.; in US patent No. 7,011,096 by Li et al.; in US patent No. 7,017,585 by Li et al.; in US Patent No. 7,025,066 by Lawson et al.; in US Patent Application Publication No. 2004-0255965 by Perfetti et al.; in PCT patent application publication WO 02/37990 by Bereman and Bombick et al., Fund. Appl. Toxicol., 39, pp. 11-17, which are incorporated herein by reference in their entirety. Additional examples of tobacco compositions that may be useful are described in US Pat. No. 7,726,320 to Robinson et al., which is incorporated herein by reference in its entirety.

[0177] In various embodiments, the filler material may comprise other fibrous materials, including, but not limited to, flax, hemp, sisal, rice stalks, and/or esparto. In various other embodiments, the filler material may comprise reconstituted tobacco itself or may be combined with other filler materials. Examples of technologies and methods for providing reconstituted tobacco leaf, including casting and papermaking technologies, are set forth in US Pat. No. 4,674,519 to Keritsis et al.; in US patent No. 4,941,484 by Clapp et al.; in US patent No. 4,987,906 by Young et al.; in US Patent No. 4,972,854 by Kiernan Jr. and etc.; in US patent No. 5,099,864 by Young et al.; in US patent No. 5,143,097 by Sohn et al.; in US patent No. 5,159,942 by Brinkley et al.; in US patent No. 5,322,076 by Brinkley et al.; in US patent No. 5,339,838 by Young et al.; in US patent No. 5,377,698 by Litzinger et al.; in US patent No. 5,501,237 by Young et al.; US Pat. No. 6,216,707 to Kumar, each of which is incorporated herein by reference in its entirety. In some examples, processed tobacco, such as certain types of reconstituted tobacco, may be used as the longitudinally extending strands. See, for example, the type of configuration set forth in US Pat. No. 5,025,814 to Raker, which is incorporated herein by reference in its entirety. In addition, specific types of reconstituted tobacco sheets can be formed, rolled, or assembled into the desired configuration. In still other embodiments, the fibrous material may comprise various types of inorganic fibers (eg, fiberglass, metal wires/screens, and the like) and/or (organic) synthetic polymers. In various embodiments, these "fibrous" materials may be unstructured (eg, randomly distributed as cellulose fibers in a molded tobacco sheet) or structured (eg, wire mesh).

[0178] In some embodiments, the aerosol-forming material may contain glycerin or propylene glycol. Preferred aerosol-forming materials include polyhydric alcohols (eg, glycerin, propylene glycol and triethylene glycol) and/or water and any other materials that form a visible aerosol, as well as any combination thereof. Representative types of aerosol-forming materials are listed in US Pat. No. 4,793,365 to Sensabaugh, Jr. et al. and No. 5,101,839 by Jakob et al., in PCT patent application WO 98/57556 by Biggs et al., and in the monograph Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco (Chemical and biological studies of new cigarette prototypes that heat tobacco instead of burning it) from the tobacco company R.J. Reynolds (1988), which are incorporated herein by reference in their entirety.

[0179] As stated above, the present invention includes a binder material. In the embodiment shown, the binder material comprises ammonium alginate. Preferred binder materials include alginates such as ammonium alginate, propylene glycol alginate, potassium alginate and sodium alginate. Alginates, and in particular high viscosity alginates, can be used in combination with controlled levels of free calcium ions. Other suitable binders include hydroxypropyl cellulose, such as Klucel H, available from Aqualon Co.; hydroxypropyl methylcellulose such as Methocel K4MS available from The Dow Chemical Co.; hydroxyethylcellulose such as Natrosol 250 MRCS manufactured by Aqualon Co.; microcrystalline cellulose such as Avicel manufactured by FMC; methylcellulose such as Methocel A4M available from The Dow Chemical Co.; and sodium carboxymethylcellulose such as CMC 7HF and CMC 7H4F available from Hercules Inc. Still other possible binders include starches (eg, corn starch), guar gum, carrageenan, locust bean gum, pectins, and xanthan gum. In some embodiments, combinations or mixtures of two or more binder materials may be used. Other examples of binder materials are described, for example, in US Patent No. 5,101,839 to Jakob et al., and US Patent No. 4,924,887 to Raker et al., each of which is incorporated herein by reference in its entirety. In some embodiments, the aerosol-forming material may be provided as part of a binder material (eg, propylene glycol alginate). Additionally, in some embodiments, the binder material may comprise nanocellulose derived from tobacco or other biomass. In some other embodiments, the binder may include cyclodextrin.

[0180] Some embodiments may further contain additional components, such as, for example, a heat retardant material or a non-flammable/burn retardant material such as ammonium phosphate. In some embodiments, nonflammable/flame retardant materials and additives may be included in the backing sheet and may include organophosphates, borax, aluminum hydroxide, graphite, potassium tripolyphosphate, dipentaerythritol, pentaerythritol, and polyols. Other substances may also be used, such as phosphonic acid nitrogen salts, monoammonium phosphate, ammonium polyphosphate, ammonium bromide, ammonium borate, ethanolammonium borate, ammonium sulfamate, halogenated organic compounds, thiourea and antimony oxide. In each aspect of the non-flammable, flame retardant and/or burn-resistant materials used in the support material and/or other components (whether alone or in combination with each other and/or with other materials) the desired properties are preferably provided without undesirable outgassing or melting. Various methods of incorporating tobacco into smoking articles and, in particular, smoking articles that are designed so as not to specifically burn substantially all of the tobacco in the smoking articles are described in US Pat. No. 4,947,874 to Brooks et al.; US Patent No. 7,647,932 by Cantrell et al.; US Patent No. 8,079,371 by Robinson et al.; US Patent No. 7,290,549 by Banerjee et al.; and US Patent Application Publication No. 2007/0215167 to Crooks et al., the disclosure of which is incorporated herein by reference in its entirety. Additional additives and other possible enhancement constituents are described in US Patent Application No. 15/707,461 to Phillips et al., which is incorporated herein by reference in its entirety.

[0181] The aerosol generating substrate may also include a plurality of thermally conductive components. In various embodiments, the thermally conductive components may be made of a metallic material, a metal alloy material, a ceramic material, a polymeric fibrous material coated with a metallic material, a carbon material (eg, graphite), or any combination thereof. Additionally, in various embodiments, the plurality of thermally conductive components may take granular form, powder form, fibrous form, mesh form, fibrous fabric form, or any combination thereof. In the illustrated embodiment, the thermally conductive components comprise a plurality of metal fibers 202 that are mixed with other components of the backing sheet 200 (eg, filler fibrous material, aerosol-forming material, binder material). In some embodiments, the backing material may comprise a molded sheet into which thermally conductive components are incorporated and/or applied. In other embodiments, the support material may comprise a combination of cast sheet and reconstituted tobacco in which thermally conductive components are included and/or applied. In yet other embodiments, the support material may comprise reconstituted tobacco into which thermally conductive components are included and/or applied. Specifically, in some embodiments, the support material may comprise from about 75% to 100% (and in some embodiments about 90%) cast sheet and from about 0% to 25% (and in some embodiments about 10%) reconstituted tobacco in addition to heat-conducting components. In other embodiments, the support material may contain approximately 100% reconstituted tobacco in addition to thermally conductive components. In various embodiments, the amount of thermally conductive constituents and/or the amount of non-conductive materials may be varied in accordance with the specific requirements of the substrate material and/or the aerosol source element including the substrate material.

[0182] Likewise, in various embodiments, the relative number of elements within each component may vary in accordance with the particular requirements of the substrate material and/or the aerosol source element including the support material. For example, in one embodiment that includes a cast sheet component and a reconstituted tobacco component, the amount of aerosol-forming material (e.g., glycerin) in the cast sheet component may be from about 30% to 60%, and the amount of aerosol-forming material (e.g. , glycerol), in the reconstituted tobacco component may be from approximately 10% to 25%. In another embodiment that includes approximately 100% reconstituted tobacco, the amount of aerosol forming material (e.g., glycerin) may be from about 5% to 40%, and the amount of aerosol forming material (e.g., glycerin) in the reconstituted tobacco component may range from approximately 10% to 25%.

[0183] In the illustrated embodiment, the non-thermal conductive components of the backing sheet 200 may comprise approximately 38% cut tobacco, approximately 53% glycerol, approximately 6% ammonium alginate, and approximately 3% ammonium phosphate. In another related but non-tobacco embodiment, the backing sheet 200 may comprise about 38% cellulose, about 53% glycerol, about 6% ammonium alginate, and about 3% ammonium phosphate. In yet another suitable embodiment, the support sheet may comprise about 90% reconstituted tobacco, about 8% cellulose pulp, about 6% ammonium alginate, and about 2% potassium carbonate. In some embodiments, the reconstituted tobacco may have an aerosol-forming material absorbed and/or loaded upon it. For example, some embodiments may have glycerin loaded on the reconstituted tobacco in the range of 20% to 50% or therein. Regardless of the composition of the remaining mixture, it should be noted that the amount of thermally conductive constituents added to the mixture may vary among different embodiments, and thus the relative amount of thermally conductive constituents may be adjusted to meet specific requirements. It should be noted that the thermally conductive components, as well as any other parts or components of the substrate materials and aerosol source elements shown in the drawings of the present invention, are depicted as such for ease of illustration, and thus the relative size and shape of the thermally conductive components and other parts or components of substrate materials and aerosol source elements do not necessarily reflect the size and shape of such elements in practice.

[0184] In any case, in some embodiments, the backing sheet 200 may be manufactured using a casting process such as that described in US Pat. No. 5,697,385 to Seymour et al., the disclosure of which is incorporated herein by reference in its entirety. For example, a fibrous filler material, an aerosol-forming material, a binder material, and a plurality of thermally conductive constituents may be mixed together to form a slurry that can be cast onto a surface (such as, for example, a moving belt). The cast slurry may then undergo one or more drying and/or processing steps such that it results in a sheet of relatively constant thickness. In the case of the illustrated embodiment, the resulting substrate sheet 200 includes a plurality of metal fibers 202 randomly (or substantially randomly) distributed throughout the thickness of the substrate sheet 200. Thus, by substantially randomly distributing thermally conductive constituents within the substrate sheet, the thermal conductivity of the substrate sheet (or a substrate-like portion created from the substrate sheet) can be increased in all directions. Other examples of casting and papermaking technologies are set forth in US Patent No. 4,674,519 by Keritsis et al.; in US patent No. 4,941,484 by Clapp et al.; in US patent No. 4,987,906 by Young et al.; in US Patent No. 4,972,854 by Kiernan Jr. and etc.; in US patent No. 5,099,864 by Young et al.; in US patent No. 5,143,097 by Sohn et al.; in US patent No. 5,159,942 by Brinkley et al.; in US patent No. 5,322,076 by Brinkley et al.; in US patent No. 5,339,838 by Young et al.; in US patent No. 5,377,698 by Litzinger et al.; in US patent No. 5,501,237 by Young et al.; in US Pat. No. 6,216,706 to Kumar, the disclosures of which are incorporated herein by reference in their entirety.

[0185] In FIG. 5 is a schematic illustration of a substrate sheet 300 according to another exemplary embodiment of the disclosure of the present invention. In particular, in FIG. 5 shows a cast substrate sheet 300 containing an aerosol generating substrate. In the specific embodiment shown in FIG. 5, the substrate sheet 300 contains a mixture of fibrous filler material, an aerosol-forming material, a binder material, and a plurality of thermally conductive constituents. As noted above, in various embodiments, the thermally conductive components may be made of a metal material, a metal alloy material, a ceramic material, a carbon material (eg, graphite), a polymeric fibrous material coated with a metal material, and/or any combination thereof. Additionally, in various embodiments, the plurality of thermally conductive components may take granular form, powder form, fibrous form, mesh form, fibrous fabric form, and/or any combination thereof.

[0186] In the illustrated embodiment, the thermally conductive components comprise a series of strips 302 separated by a series of spaces 304 therebetween, thereby forming a segmented pattern. Moreover, in the illustrated embodiment, a series of strips 302 containing thermally conductive components are formed on the surface of the substrate sheet 300. It should be noted that although the strips 302 are shown substantially transverse to the longitudinal axis of the sheet 300, in other embodiments the strips may be configured at any angle relative to the longitudinal axis of the sheet, including, for example, substantially parallel to the longitudinal axis of the sheet or at an angle relative to the longitudinal axis leaf. Thus, as will be described in more detail below, in various embodiments of the aerosol source element in which a backing sheet is used as the outer wrapping sheet of the support, the resulting stripes can have any orientation relative to the longitudinal axis of the aerosol source element, including, for example, , substantially transverse to the longitudinal axis of the aerosol source element (see, for example, FIGS. 8 and 9) or, for example, substantially parallel to the longitudinal axis of the aerosol source element or located at an angle relative to the longitudinal axis of the source element.

[0187] In various embodiments, before adding thermally conductive components, the substrate sheet 300 may be constructed as described above. For example, although the relative amounts of other (i.e., non-thermal conductive constituents) components of the backing sheet 300 may vary, in some embodiments, these components of the backing sheet 300 may contain about 38% cut tobacco, about 53% glycerin, about 6% ammonium alginate, and about 3% ammonium phosphate. In other embodiments, sheet 300 may contain about 38% cellulose, about 53% glycerol, about 6% ammonium alginate, and about 3% ammonium phosphate. As noted above, in some embodiments, the substrate sheet 300 may be produced by casting. For example, the fibrous filler material, the aerosol-forming material, and the binder material can be mixed together to form a slurry that can be cast onto a surface (such as, for example, a moving belt). The cast slurry may then undergo one or more drying and/or processing steps such that it results in a sheet of relatively constant thickness. As stated above, regardless of the composition of the remaining mixture, it should be noted that the amount of thermally conductive constituents added to the mixture may vary among different embodiments, and thus the relative amount of thermally conductive constituents can be adjusted to meet specific requirements.

[0188] In various embodiments, the segmented pattern can be created in a variety of ways, including, for example, selective adhesion, metal printing, layering and/or stitching on the formed substrate sheet 300. For example, in one embodiment, stripes 302 may be created by selectively powder coating thermally conductive components on the surface of substrate sheet 300. In other embodiments, the stripes 302 may be created by electrostatically attracting thermally conductive components on the surface of the substrate sheet 300 and adhering the material in a segmented pattern to the substrate sheet 300. In another embodiment, stripes 302 may be created using a masking template. In another embodiment, the stripes 302 may be created by printing a conductive metal material (ie, thermally conductive components) onto the surface of the substrate sheet 300 in a segmented pattern. In another embodiment, the surface of the backing sheet 300 may be stitched with thermally conductive components (eg, in the form of conductive threads) to thereby form a segmented pattern. Thus, by arranging the thermal conductive components in a segmented pattern on the substrate sheet, the thermal conductivity of the substrate sheet or a substrate portion formed from the substrate sheet can be increased in one direction.

[0189] In FIG. 14 is a schematic illustration of a substrate sheet 1200 according to another exemplary embodiment of the disclosure of the present invention. In particular, in FIG. 14 shows a cast substrate sheet 1200 containing an aerosol generating substrate. In the specific embodiment shown in FIG. 14, backing sheet 1200 contains a mixture of fibrous filler material, aerosol-forming material, binder material, and a plurality of thermally conductive constituents. As noted above, in various embodiments, the thermally conductive components may be made of a metal material, a metal alloy material, a ceramic material, a carbon material (eg, graphite), a polymeric fibrous material coated with a metal material, and/or any combination thereof. Additionally, in various embodiments, the plurality of thermally conductive components may take granular form, powder form, fibrous form, mesh form, fibrous fabric form, or any combination thereof. In the illustrated embodiment, the thermally conductive components comprise a metal mesh 1202 that is applied in layers to a substrate sheet 1200. It should be noted that although the strips 1202 are shown such that their pattern is substantially aligned with the longitudinal axis of the sheet 1200, in other embodiments the grid may be configured at any angle relative to the longitudinal axis of the sheet. Thus, as will be described in more detail below, in various embodiments of the aerosol source element in which a backing sheet is used as the outer wrapping sheet of the substrate, the mesh can be in any orientation relative to the longitudinal axis of the aerosol source element.

[0190] In various embodiments, before adding thermally conductive components, the substrate sheet 1200 may be constructed as described above. For example, although the relative amounts of other (i.e., non-thermal conductive components) components of the backing sheet 1200 may vary, in some embodiments, these components of the backing sheet 300 may contain about 38% cut tobacco, about 53% glycerin, about 6% ammonium alginate, and about 3% ammonium phosphate. In other embodiments, sheet 300 may contain about 38% cellulose, about 53% glycerol, about 6% ammonium alginate, and about 3% ammonium phosphate. As noted above, in some embodiments, the substrate sheet 1200 may be produced by casting. For example, the fibrous filler material, the aerosol-forming material, and the binder material can be mixed together to form a slurry that can be cast onto a surface (such as, for example, a moving belt). The cast slurry may then undergo one or more drying and/or processing steps such that it results in a sheet of relatively constant thickness. As stated above, regardless of the composition of the remaining mixture, it should be noted that the amount of thermally conductive constituents added to the mixture may vary among different embodiments, and thus the relative amount of thermally conductive constituents can be adjusted to meet specific requirements.

[0191] In FIG. 6 is a schematic illustration of an aerosol source element 400 according to an example embodiment of the present disclosure. In the illustrated embodiment, the aerosol source element 400 includes a substrate portion 402 and a mouthpiece portion 404. In various embodiments, the substrate portion 402 may comprise a plurality of mixed pieces 406 that are cut from the original substrate sheet. For example, in the illustrated embodiment, a plurality of mixed pieces 406 are cut from a parent substrate sheet similar or substantially the same as the substrate sheet 200 described above with reference to FIG. 4. Thus, the composition and construction of the individual pieces 406 may be similar or substantially the same as described above with respect to the backing sheet 200. In particular, the mixed pieces 406 of the illustrated embodiment may begin as a starting substrate sheet that contains a mixture of fibrous filler material, aerosol-forming material, binder material, and a plurality of thermally conductive constituents. Reference is made to the discussion above regarding the various possible filler materials, aerosol-forming materials, binders and thermally conductive constituents for use in the base sheet, as well as the possible relative amounts of each. The original substrate sheet can then be cut into a plurality of pieces (eg, strips, segments, pieces, and the like) and assembled for use as a substrate portion 402 of the aerosol source element 400. In various embodiments, the original backing sheet may be cut in a variety of different ways. For example, in one embodiment, the original backing sheet may be cut by a mechanical cutting machine (eg, a guillotine and/or a paper chip cutting machine). In other embodiments, the original substrate sheet may be cut by a laser cutting device and/or water jet cutting device. In other embodiments, the original substrate sheet may be fibrillated. In other embodiments, a hammer mill may be used to reduce the size of the original backing sheet, and then the resulting sheet may be subsequently cut using one or more of the methods described above.

[0192] As described above, in some embodiments, a precursor sheet of substrate can be manufactured using a casting process in which a fibrous filler material, an aerosol-forming material, and a plurality of thermally conductive constituents can be mixed together to form a slurry that can be cast onto surface (such as a moving belt). The cast slurry may then undergo one or more drying and/or processing steps such that it results in a starting sheet of relatively constant thickness. In the case of the illustrated embodiment, the resulting starting sheet may include a plurality of metal fibers randomly (or substantially randomly) distributed throughout the thickness of the sheet.

[0193] In various embodiments, the mouthpiece portion 404 of the aerosol source element 400 may comprise a plurality of materials, which in some embodiments may include a filter as described above. Other materials that may be located in the tip portion 404, alone or in any combination, include, but are not limited to, tobacco blends, one or more flavors, voids, and/or phase change materials. The mouth end portion 404 may also include a hollow tubular structure. In various embodiments, such a tube may be made from a variety of materials and may contain one or more adhesives. Examples of materials include, but are not limited to, paper, paper layers, paperboard, plastic, corrugated cardboard and/or composite materials.

[0194] In various embodiments, tobacco blends may contain various types and forms of tobacco in the form of mixed cut filler. For example, some popular tobacco blends for cigarette production, commonly referred to as "American blends," include blends of cut or shredded pieces of fire-cured tobacco, Barley tobacco, and Oriental tobacco; and such blends in many cases also contain processed tobacco pieces, such as processed tobacco stems, expanded tobacco and/or reconstituted tobacco. The exact amount of each type or form of tobacco in the tobacco blend used to produce a particular smoking product may vary and is a design choice based on factors such as desired sensory characteristics (eg, taste and aroma). See, for example, the types of tobacco blends described in Tobacco Encyclopedia, Voges (ed.) pp. 44-45 (1984), Browne, The Design of Cigarettes, 3rd ed., 43 pages (1990) and in Tobacco Production, Chemistry and Technology, Davis et al. (ed.) 346 pages (1999). See also the representative types of tobacco blends listed in US Patent No. 4,836,224 by Lawson et al.; in US patent No. 4,924,888 by Perfetti et al.; in US patent No. 5,056,537 by Brown et al.; in US Patent No. 5,220,930 by Gentry; in US Patent Application Publications No. 2004/0255965 to Perfetti et al. and No. 2005/0066986 to Nestor et al.; in PCT Application Publication WO 02/37990 by Bereman and Bombick et al., Fund. Appl. Toxicol., 39, pp. 11-17, the disclosures of which are incorporated herein by reference in their entirety.

[0195] As used herein, reference to “flavor” refers to compounds or components that can be aerosolized or delivered to a user and that impart a sensory experience of taste and/or aroma. Examples of flavors include, but are not limited to, vanillin, ethyl vanillin, cream, tea, coffee, fruit (such as apple, cherry, strawberry, peach, and citrus flavors including lime and lemon), maple, menthol, mint, peppermint, spearmint, wintergreen, nutmeg, cloves, lavender, cardamom, ginger, honey, anise, sage, rosemary, hibiscus, rosehip, mate, gayusa, honeybush, rooibos, Eriodictyon Californian, bacopa monnieri, ginko biloba, withania somnifera, cinnamon, sandalwood, jasmine, cascarrolle, cocoa, licorice and flavorings and additives of a type and nature traditionally used to flavor cigarette, cigar and pipe tobacco. In addition, syrups such as high fructose corn syrup may be used. Exemplary plant-derived compositions that may be useful are described in US Patent No. 9,107,453 and US Patent Application Publication No. 2012/0152265 to Dube et al., the disclosures of which are incorporated herein by reference in their entirety. The choice of such additional components varies depending on factors such as sensory characteristics that are desired for the smoking article, and the present invention covers any such additional components that are readily apparent to those skilled in the art of tobacco and tobacco-related or tobacco-derived products. See: for example, Gutcho, Tobacco Flavoring Substances and Methods, Noyes Data Corp. (1972), and Leffingwell et al., Tobacco Flavoring for Smoking Products (1972), the disclosure of which is incorporated herein by reference in its entirety. It should be noted that reference to a flavor need not be limited to any one flavor as described above, and may in fact be a combination of one or more flavors.

[0196] Some examples of suitable phase change materials include, but are not limited to, salts such as AgNO ₃ , AlCl ₃ , TaCl ₃ , InCl ₃ , SnCl ₂ , AlI ₃ and TiI ₄ ; metals and metal alloys such as selenium, tin, indium, tin-zinc, indium-zinc or indium-bismuth, and organic compounds such as D-mannitol, succinic acid, p-nitrobenzoic acid, hydroquinone and adipic acid. Other examples are described in US Patent No. 8,430,106 to Potter et al., which is incorporated herein by reference in its entirety.

[0197] In FIG. 7 is a schematic illustration of an aerosol source element 500 according to an example embodiment of the present disclosure. In the illustrated embodiment, the aerosol source element 500 includes a substrate portion 502 and a mouthpiece portion 504. In various embodiments, the substrate portion 502 may comprise a series of overlapping layers 506 of the original substrate sheet (eg, an assembled web containing the original substrate sheet). For example, in the illustrated embodiment, the sequence of overlapping layers 506 comprises a sequence of layers of a parent substrate sheet similar or substantially the same as the substrate sheet 200 described above with reference to FIG. 4. In another embodiment, the sequence of overlapping layers 506 of the original backing sheet may be similar to, or may be substantially the same as, the backing sheet 1200 of FIG. 14. Thus, the composition and construction of the layers may be similar or substantially the same as described above with respect to the backing sheet 200 or the backing sheet 1200. In particular, the overlapping layers of the illustrated embodiment may begin as a starting backing sheet that contains a mixture of fibrous filler material, an aerosol-forming material, a binder material, and a plurality of thermally conductive constituents. Reference is made to the discussion above regarding the various possible filler materials, aerosol-forming materials, binders and thermally conductive constituents for use in the base sheet, as well as the possible relative amounts of each. The original backing sheet may then be lapped (eg, a gathered web) for use as a backing portion 502 of the aerosol source element 500. It should be noted that, in various embodiments, the term “overlapping layers” may also include bundled, chipped, and/or otherwise assembled layers in which the individual layers may not be obvious.

[0198] In various embodiments, the mouthpiece portion 504 may contain a variety of materials, which in some embodiments may include a filter as described above. Other materials that may be located in the mouthpiece portion, alone or in any combination, include, but are not limited to, tobacco blends, one or more flavors, voids, and/or phase change materials. The mouth end portion 404 may also include a hollow tubular structure. In various embodiments, such a tube may be made from a variety of materials and may contain one or more adhesives. Examples of materials include, but are not limited to, paper, paper layers, paperboard, plastic, corrugated cardboard and/or composite materials. Reference is made to the discussion of these components above with respect to FIG. 6.

[0199] In FIG. 8 is a schematic illustration of an aerosol source element 600 according to an example embodiment of the present disclosure. In the illustrated embodiment, aerosol source member 600 includes a substrate portion 602, a mouth end portion 604, and an outer substrate wrap sheet 608 extending around at least a portion of the substrate portion 602. In various embodiments, the outer backing sheet 608 may be separated from the optional outer wrapping material, as described above. In various embodiments, the substrate portion 602 may comprise a plurality of mixed pieces 606 that are cut from the original substrate sheet. For example, in the illustrated embodiment, a plurality of mixed pieces 606 are cut from a parent substrate sheet similar or substantially the same as the substrate sheet 200 described above with reference to FIG. 4. Thus, the composition and construction of the individual pieces 606 may be similar or substantially the same as described above with respect to the sheet 200. In particular, the mixed pieces 606 of the illustrated embodiment may begin as an original backing sheet that contains a mixture of fibrous filler material , an aerosol-forming material, a binder material and a variety of thermally conductive components. Reference is made to the discussion above regarding the various possible filler materials, aerosol-forming materials, binders and thermally conductive constituents for use in the base sheet, as well as the possible relative amounts of each. The original substrate sheet can then be cut into a plurality of pieces (eg, strips, segments, pieces, and the like) and assembled for use as a substrate portion 602 of the aerosol source element 600.

[0200] As described above, in some embodiments, a precursor sheet of substrate can be manufactured using a casting process in which a fibrous filler material, an aerosol-forming material, and a plurality of thermally conductive constituents can be mixed together to form a slurry that can be cast onto surface (such as a moving belt). The cast slurry may then undergo one or more drying and/or processing steps such that it results in a starting sheet of relatively constant thickness. In the case of the illustrated embodiment, the resulting starting sheet may include a plurality of metal fibers randomly (or substantially randomly) distributed throughout the thickness of the sheet.

[0201] As noted above, the aerosol source element 600 of the illustrated embodiment also includes an outer substrate wrap sheet 608 that extends around at least a portion of the substrate portion 602. In the illustrated embodiment, the outer backing wrap sheet 608 is similar or substantially the same as the backing sheet 300 described above with reference to FIG. 5. Thus, the composition and construction of the outer wrapping backing sheet 608 may be similar or substantially the same as described above with respect to the backing sheet 300. For example, in the illustrated embodiment, the outer backing sheet 608 comprises a mixture of a fibrous filler material, an aerosol-forming material, a binder material, and a plurality of thermally conductive constituents. As noted above, in various embodiments, the thermally conductive components may be made of a metallic material, a metal alloy material, a ceramic material, a polymeric fibrous material coated with a metallic material, or any combination thereof. Additionally, in various embodiments, the plurality of thermally conductive components may take granular form, powder form, fibrous form, mesh form, fibrous fabric form, or any combination thereof. In the illustrated embodiment, the thermally conductive components comprise a series of strips 612 separated by a series of spaces 614 between them, thereby forming a segmented pattern. In addition, in the illustrated embodiment, a series of strips 612 that contain thermally conductive components are formed on the surface of the outer substrate wrap sheet 608. Additional reference is made to the discussion above regarding the various possible filler materials, aerosol-forming materials, binders and thermally conductive constituents for use in the base substrate sheet, as well as the possible relative amounts of each.

[0202] As discussed above, in some embodiments, the outer substrate wrap sheet 608 may be produced by casting. For example, the fibrous filler material, the aerosol-forming material, and the binder material can be mixed together to form a slurry that can be cast onto a surface (such as, for example, a moving belt). The cast slurry may then undergo one or more drying and/or processing steps such that it results in a sheet of relatively constant thickness.

[0203] In various embodiments, the segmented pattern may be created by a variety of methods, including, for example, selective adhesion, metal printing, layering, and/or stitching on the formed outer wrap sheet 608. For example, in one embodiment, stripes 612 may be created by selectively powder coating a thermally conductive material on the surface of the outer substrate wrap sheet 608. In other embodiments, the stripes 612 may be created by electrostatically attracting a thermally conductive material to the surface of the outer backing wrap sheet 608 and adhering the material in a segmented pattern to the outer backing wrapping sheet 608. In another embodiment, stripes 612 may be created using a masking template. In other embodiments, the stripes 612 may be created by printing a conductive metal material onto the surface of the outer substrate wrap sheet 608 in a segmented pattern. In another embodiment, the surface of the outer backing wrap sheet 608 may be stitched with thermally conductive materials (eg, in the form of conductive threads) to thereby form a segmented pattern. As discussed above, in various embodiments of the aerosol source element in which a substrate sheet is used as the outer wrapping sheet of the substrate, the resulting stripes may have any orientation relative to the longitudinal axis of the aerosol source element, including, for example, stripes that are substantially transverse to the longitudinal axis of the aerosol source element, such as the illustrated embodiment. In other embodiments, the stripes may have any other angle relative to the longitudinal axis of the aerosol source element, including, for example, substantially parallel to the longitudinal axis of the aerosol source element or angled to the longitudinal axis of the aerosol source element.

[0204] In various embodiments, the mouthpiece portion 604 may contain a variety of materials, which in some embodiments may include a filter as described above. Other materials that may be located in the mouthpiece portion, alone or in any combination, include, but are not limited to, tobacco blends, one or more flavors, voids, and/or phase change materials. The mouth end portion 404 may also include a hollow tubular structure. In various embodiments, such a tube may be made from a variety of materials and may contain one or more adhesives. Examples of materials include, but are not limited to, paper, paper layers, paperboard, plastic, corrugated cardboard and/or composite materials. Reference is made to the discussion of these components above with respect to FIG. 6.

[0205] In FIG. 9 is a schematic illustration of an aerosol source element 700 according to an example embodiment of the present disclosure. In the illustrated embodiment, aerosol source member 700 includes a substrate portion 702, a mouth end portion 704, and an outer substrate wrap sheet 708 extending around at least a portion of the substrate portion 702. In various embodiments, the outer backing sheet 708 may be separated from the optional outer wrapping material, as described above. In various embodiments, the substrate portion 702 may comprise a series of overlapping layers 706 of the original substrate sheet (eg, an assembled web containing the original substrate sheet). For example, in the illustrated embodiment, the sequence of overlapping layers 706 comprises layers of a parent substrate sheet similar or substantially the same as the substrate sheet 200 described above with reference to FIG. 4. In another embodiment, the sequence of overlapping layers 506 of the original backing sheet may be similar to, or may be substantially the same as, the backing sheet 1200 of FIG. 14. Thus, the composition and construction of the layers may be similar or substantially the same as described above with respect to sheet 200 or sheet 1200. Specifically, the overlapping layers of the illustrated embodiment may begin as a parent backing sheet that contains a mixture of fibrous filler material , an aerosol-forming material, a binder material and a variety of thermally conductive components. Reference is made to the discussion above regarding the various possible filler materials, aerosol-forming materials, binders and thermally conductive constituents for use in the base sheet, as well as the possible relative amounts of each.

[0206] As described above, in some embodiments, a precursor sheet of substrate can be manufactured using a casting process in which a fibrous filler material, an aerosol-forming material, and a plurality of thermally conductive constituents can be mixed together to form a slurry that can be cast onto surface (such as a moving belt). The cast slurry may then undergo one or more drying and/or processing steps such that it results in a starting sheet of relatively constant thickness. In the case of the illustrated embodiment, the resulting starting sheet may include a plurality of metal fibers randomly (or substantially randomly) distributed throughout the thickness of the sheet. In some embodiments, the original backing sheet may be a reconstituted tobacco sheet, as described above.

[0207] As noted above, the aerosol source element 700 of the illustrated embodiment also includes an outer substrate wrap sheet 708 that extends around at least a portion of the substrate portion 702. In the illustrated embodiment, the outer wrapping backing sheet 708 is similar or substantially the same as the backing sheet 300 described above with reference to FIG. 5. Thus, the composition and construction of the outer wrapping backing sheet 708 may be similar or substantially the same as described above with respect to the backing sheet 300. For example, in the illustrated embodiment, the outer backing sheet 708 comprises a mixture of a fibrous filler material, an aerosol-forming material, a binder material, and a plurality of thermally conductive constituents. As noted above, in various embodiments, the thermally conductive components may be made of a metallic material, a metal alloy material, a ceramic material, a polymeric fibrous material coated with a metallic material, or any combination thereof. Additionally, in various embodiments, the plurality of thermally conductive components may take granular form, powder form, fibrous form, mesh form, fibrous fabric form, or any combination thereof. In the illustrated embodiment, the thermally conductive components comprise a series of strips 712 separated by a series of spaces 714 between them, thereby forming a segmented pattern. In addition, in the illustrated embodiment, a series of strips 712 that contain thermally conductive components are formed on the surface of the outer substrate wrap sheet 708. Additional reference is made to the discussion above regarding the various possible filler materials, aerosol-forming materials, binders and thermally conductive constituents for use in the base substrate sheet, as well as the possible relative amounts of each.

[0208] As discussed above, in some embodiments, the outer substrate wrap sheet 708 may be formed by casting. For example, the fibrous filler material, the aerosol-forming material, and the binder material can be mixed together to form a slurry that can be cast onto a surface (such as, for example, a moving belt). The cast slurry may then undergo one or more drying and/or processing steps such that it results in a sheet of relatively constant thickness.

[0209] In various embodiments, the segmented pattern can be created in a variety of ways, including, for example, selective adhesion, metal printing, layering and/or stitching on the formed outer substrate wrap sheet 708. For example, in one embodiment, stripes 712 may be created by selectively powder coating a thermally conductive material on the surface of the outer backing wrap sheet 708. In other embodiments, the stripes 712 may be created by electrostatically attracting a thermally conductive material to the surface of the outer backing wrap sheet 708 and adhering the material in a segmented pattern to the outer backing wrapping sheet 708. In another embodiment, stripes 712 may be created using a masking template. In other embodiments, stripes 712 may be created by printing a conductive metal material onto the surface of the outer substrate wrap sheet 708 in a segmented pattern. In another embodiment, the surface of the outer backing wrap sheet 708 may be stitched with thermally conductive materials (eg, in the form of conductive threads) to thereby form a segmented pattern. As discussed above, in various embodiments of the aerosol source element in which a substrate sheet is used as the outer wrapping sheet of the substrate, the resulting stripes may have any orientation relative to the longitudinal axis of the aerosol source element, including, for example, stripes that are substantially transverse to the longitudinal axis of the aerosol source element, such as the illustrated embodiment. In other embodiments, the stripes may be at any other angle relative to the longitudinal axis of the aerosol source element, including, for example, substantially parallel to the longitudinal axis of the aerosol source element or angled to the longitudinal axis of the source element.

[0210] As discussed above, in various embodiments, the mouthpiece portion 704 may contain a variety of materials, which in some embodiments may include a filter as described above. Other materials that may be located in the mouthpiece portion, alone or in any combination, include, but are not limited to, tobacco blends, one or more flavors, voids, and/or phase change materials. The mouth end portion 404 may also include a hollow tubular structure. In various embodiments, such a tube may be made from a variety of materials and may contain one or more adhesives. Examples of materials include, but are not limited to, paper, paper layers, paperboard, plastic, corrugated cardboard and/or composite materials. Reference is made to the above discussion of these components with respect to FIG. 6.

[0211] In FIG. 15 is a schematic illustration of an aerosol source element 1300 according to an example implementation of the disclosure of the present invention. In the illustrated embodiment, aerosol source member 1300 includes a substrate portion 1302, a mouthpiece end portion 1304, and an outer substrate wrap sheet 1308 extending around at least a portion of the substrate portion 1302. In various embodiments, the outer backing sheet 1308 may be separated from the optional outer wrapping material, as described above. In various embodiments, the substrate portion 1302 may comprise a plurality of mixed pieces 1306 that are cut from the original substrate sheet. For example, in the illustrated embodiment, a plurality of mixed pieces 1306 are cut from a parent substrate sheet similar or substantially the same as the substrate sheet 200 described above with reference to FIG. 4. Thus, the composition and construction of the individual pieces 1306 may be similar or substantially the same as described above with respect to the sheet 200. In particular, the mixed pieces 1306 of the illustrated embodiment may begin as an original backing sheet that contains a mixture of fibrous filler material , an aerosol-forming material, a binder material and a variety of thermally conductive components. Reference is made to the discussion above regarding the various possible filler materials, aerosol-forming materials, binders and thermally conductive constituents for use in the base sheet, as well as the possible relative amounts of each. The original substrate sheet can then be cut into a plurality of pieces (eg, strips, segments, pieces, and the like) and assembled for use as a substrate portion 1302 of the aerosol source element 1300.

[0212] As described above, in some embodiments, a precursor sheet of substrate can be manufactured using a casting process in which a fibrous filler material, an aerosol-forming material, and a plurality of thermally conductive constituents can be mixed together to form a slurry that can be cast onto surface (such as a moving belt). The cast slurry may then undergo one or more drying and/or processing steps such that it results in a starting sheet of relatively constant thickness. In the case of the illustrated embodiment, the resulting starting sheet may include a plurality of metal fibers randomly (or substantially randomly) distributed throughout the thickness of the sheet. In some embodiments, the original backing sheet may be a reconstituted tobacco sheet, as described above.

[0213] As noted above, the aerosol source element 1300 of the illustrated embodiment also includes an outer substrate wrap sheet 1308 that extends around at least a portion of the substrate portion 1302. In the illustrated embodiment, the outer backing wrap sheet 1308 is similar or substantially the same as the backing sheet 1200 described above with reference to FIG. 14. Thus, the composition and construction of the outer wrapping backing sheet 1308 may be similar or substantially the same as described above with respect to the backing sheet 1200. For example, in the illustrated embodiment, the outer backing sheet 1308 comprises a mixture of a fibrous filler material, an aerosol-forming material, a binder material, and a plurality of thermally conductive constituents. As noted above, in various embodiments, the thermally conductive components may be made of a metallic material, a metal alloy material, a ceramic material, a polymeric fibrous material coated with a metallic material, or any combination thereof. Additionally, in various embodiments, the plurality of thermally conductive components may take granular form, powder form, fibrous form, mesh form, fibrous fabric form, or any combination thereof. In the illustrated embodiment, the thermally conductive components comprise a metal mesh 1310 that has been deposited in layers on a substrate sheet. Additional reference is made to the discussion above regarding the various possible filler materials, aerosol-forming materials, binders and thermally conductive constituents for use in the base substrate sheet, as well as the possible relative amounts of each.

[0214] As discussed above, in some embodiments, the outer substrate wrap sheet 1308 may be produced by casting. For example, the fibrous filler material, the aerosol-forming material, and the binder material can be mixed together to form a slurry that can be cast onto a surface (such as, for example, a moving belt). The cast slurry may then undergo one or more drying and/or processing steps such that it results in a sheet of relatively constant thickness. In other embodiments, the original backing sheet may be a reconstituted tobacco sheet as described above.

[0215] As discussed above, in various embodiments of the aerosol source element in which a substrate sheet is used as the outer wrap sheet of the substrate, the resulting pattern may have any orientation relative to the longitudinal axis of the aerosol source element, including, for example, a pattern which is substantially aligned with the longitudinal axis of an aerosol source element such as the illustrated embodiment. In other embodiments, the pattern may have any other angle relative to the longitudinal axis of the aerosol source element.

[0216] In various embodiments, the mouthpiece portion 1304 may contain a variety of materials, which in some embodiments may include a filter as described above. Other materials that may be located in the mouthpiece portion, alone or in any combination, include, but are not limited to, tobacco blends, one or more flavors, voids, and/or phase change materials. The mouth end portion 404 may also include a hollow tubular structure. In various embodiments, such a tube may be made from a variety of materials and may contain one or more adhesives. Examples of materials include, but are not limited to, paper, paper layers, paperboard, plastic, corrugated cardboard and/or composite materials. Reference is made to the discussion of these components above with respect to FIG. 6.

[0217] In FIG. 16 is a schematic representation of an aerosol source element 1400 according to an example implementation of the disclosure of the present invention. In the illustrated embodiment, aerosol source member 1400 includes a substrate portion 1402, a mouthpiece end portion 1404, and an outer substrate wrap sheet 1408 extending around at least a portion of the substrate portion 1402. In various embodiments, the outer backing sheet 1408 may be separated from the optional outer wrapping material, as described above. In various embodiments, the substrate portion 1402 may comprise a series of overlapping layers 1406 of the original substrate sheet (eg, an assembled web containing the original substrate sheet). For example, in the illustrated embodiment, the sequence of overlapping layers 1406 comprises layers of a parent substrate sheet similar or substantially the same as the substrate sheet 200 described above with reference to FIG. 4. In another embodiment, the sequence of overlapping layers 1406 of the original substrate sheet may be similar or may be substantially the same as the substrate sheet 1200 of FIG. 14. Thus, the composition and construction of the layers may be similar or substantially the same as described above with respect to sheet 200 or sheet 1200. Specifically, the overlapping layers of the illustrated embodiment may begin as a parent backing sheet that contains a mixture of fibrous filler material , an aerosol-forming material, a binder material and a variety of thermally conductive components. Reference is made to the discussions above regarding the various possible filler materials, aerosol-forming materials, binders and thermally conductive constituents for use in the base sheet, as well as the possible relative amounts of each.

[0218] As described above, in some embodiments, a precursor sheet of substrate can be manufactured using a casting process in which a fibrous filler material, an aerosol-forming material, and a plurality of thermally conductive constituents can be mixed together to form a slurry that can be cast onto surface (such as a moving belt). The cast slurry may then undergo one or more drying and/or processing steps such that it results in a starting sheet of relatively constant thickness. In the case of the illustrated embodiment, the resulting starting sheet may include a plurality of metal fibers randomly (or substantially randomly) distributed throughout the thickness of the sheet. In other embodiments, the original backing sheet may be a reconstituted tobacco sheet as described above.

[0219] As discussed above, the aerosol source element 1400 of the illustrated embodiment also includes an outer substrate wrap sheet 1408 that extends around at least a portion of the substrate portion 1402. In the illustrated embodiment, the outer backing wrap sheet 1408 is similar or substantially the same as the backing sheet 1200 described above with reference to FIG. 14. Thus, the composition and construction of the outer wrapping backing sheet 1408 may be similar or substantially the same as described above with respect to the backing sheet 1200. For example, in the illustrated embodiment, the outer backing sheet 1408 comprises a mixture of fibrous filler material, an aerosol-forming material, a binder material, and a plurality of thermally conductive constituents. As noted above, in various embodiments, the thermally conductive components may be made of a metallic material, a metal alloy material, a ceramic material, a polymeric fibrous material coated with a metallic material, or any combination thereof. Additionally, in various embodiments, the plurality of thermally conductive components may take granular form, powder form, fibrous form, mesh form, fibrous fabric form, or any combination thereof. In the illustrated embodiment, the thermally conductive components comprise a metal mesh 1410 that has been deposited in layers on a substrate sheet. Additional reference is made to the discussion above regarding the various possible filler materials, aerosol-forming materials, binders and thermally conductive constituents for use in the base substrate sheet, as well as the possible relative amounts of each.

[0220] As discussed above, in some embodiments, the outer substrate wrap sheet 1408 may be produced by casting. For example, the fibrous filler material, the aerosol-forming material, and the binder material can be mixed together to form a slurry that can be cast onto a surface (such as, for example, a moving belt). The cast slurry may then undergo one or more drying and/or processing steps such that it results in a sheet of relatively constant thickness. In other embodiments, the original backing sheet may be a reconstituted tobacco sheet as described above.

[0221] As discussed above, in various embodiments of the aerosol source element in which a substrate sheet is used as the outer wrap sheet of the substrate, the resulting pattern may have any orientation relative to the longitudinal axis of the aerosol source element, including, for example, a pattern which is substantially aligned with the longitudinal axis of an aerosol source element such as the illustrated embodiment. In other embodiments, the pattern may have any other angle relative to the longitudinal axis of the aerosol source element.

[0222] As discussed above, in various embodiments, the mouthpiece portion 1404 may contain a variety of materials, which in some embodiments may include a filter as described above. Other materials that may be located in the mouthpiece portion, alone or in any combination, include, but are not limited to, tobacco blends, one or more flavors, voids, and/or phase change materials. The mouth end portion 404 may also include a hollow tubular structure. In various embodiments, such a tube may be made from a variety of materials and may contain one or more adhesives. Examples of materials include, but are not limited to, paper, paper layers, paperboard, plastic, corrugated cardboard and/or composite materials. Reference is made to the above discussion of these components with respect to FIG. 6.

[0223] In FIG. 10 illustrates various steps of a method 800 for making an aerosol generating substrate for use in an aerosol source element according to an example embodiment of the disclosure of the present invention. In various embodiments, method 800 may include providing a fibrous filler material at 802, providing an aerosol-forming material at 804, verifying a binder material at 806, and providing a plurality of thermally conductive constituents at 808. Method 800 may also include providing a substrate sheet with using the fibrous filler material, aerosol-forming material, binder material, and a plurality of thermally conductive components at step 810. In various embodiments, reference is made to the fibrous filler materials, aerosol-forming materials, and binder materials, as well as the backing sheets described above with respect to FIG. 4-5.

[0224] in FIG. 11 illustrates various steps of a method 900 for manufacturing an aerosol source element for use with an aerosol source delivery device according to an example implementation of the disclosure of the present invention. In various embodiments, method 900 may include forming a precursor sheet of substrate comprising a fibrous filler material, an aerosol delivery device, a binder material, and a plurality of thermally conductive constituents at 902. Method 900 may also include cutting the precursor sheet of substrate into a plurality of pieces at 904, forming an aggregate mixed pieces from said plurality of pieces of the original substrate sheet at step 906 and forming a substrate portion using said plurality of mixed pieces at step 908. In various embodiments, reference is made to fibrous filler materials, aerosol delivery materials, binder materials, and thermally conductive components, as well as the backing sheets described above in relation to FIG. 4-6 and 8.

[0225] In FIG. 12 illustrates various steps of a method 1000 for manufacturing an aerosol source element for use with an aerosol source delivery device according to an example embodiment of the disclosure of the present invention. In various embodiments, the method 1000 may include forming a precursor substrate sheet comprising a fibrous filler material, an aerosol delivery device, a binder material, and a plurality of thermally conductive constituents at 1002. The method 1000 may also include overlapping a plurality of layers of the precursor substrate sheet at 1004 and forming a portion at form of a substrate using said overlapping layers at step 1006. In various embodiments, reference is made to the fibrous filler materials, aerosol delivery materials, binders and thermally conductive components, as well as the substrate sheets described above with respect to FIG. 4-5, 7 and 9.

[0226] In FIG. 13 illustrates various steps of a method 1100 for manufacturing an aerosol source element for use with an aerosol source delivery device according to an example embodiment of the disclosure of the present invention. In various embodiments, method 1100 may include forming a mixture comprising a fibrous filler material, an aerosol-forming material, a binder material, and a plurality of thermally conductive constituents at step 1102. Method 1000 may also include extruding and spheronizing the mixture into a plurality of granules at step 1104, forming an aggregate beads at step 1106. The method may also include forming a support portion using said aggregate of beads at step 1108. It should be noted that in some embodiments, the beads may be encapsulated spheres.

[0227] The present invention provides aerosol generating substrates and aerosol source elements for use in aerosol delivery devices that use electrical energy to heat a heating element, which in turn heats the substrate material (preferably without burning the substrate material to any significant extent). degree) to form an inhalable substance such as an aerosol; Moreover, such devices are compact enough to be considered portable devices. In some embodiments, such devices may be specifically characterized as smoking articles. As used herein, the term is intended to refer to a device or article that provides the taste and/or feel (eg, hand feel or mouth feel) of smoking a cigarette, cigar, or pipe without actually burning any component of the device. The term "smoking device" or "article" does not necessarily mean that during operation the device emits smoke in the sense of a by-product of combustion or pyrolysis. Rather, smoking refers to the physical actions of a person while using a device—for example, holding the device in the hand, taking a puff on one end of the device, and inhaling through the device. In additional embodiments, the devices of the invention may be characterized as vapor generating devices, aerosolization devices, or pharmaceutical delivery devices. Thus, such devices may be configured to deliver one or more substances in an inhalable state.

[0228] As stated above, although the aerosol source element and the control body may be provided together as a finished smoking article or pharmaceutical delivery article, typically the components may be provided separately. For example, the present invention also includes a disposable unit for use with a reusable smoking article or a reusable pharmaceutical delivery article. In specific embodiments, such a disposable unit (which may be an aerosol source element, as shown in the accompanying drawings) may comprise a generally tubular-shaped body having a heated end configured to engage a reusable smoking or pharmaceutical delivery product, an opposite mouthpiece end configured to allow inhalable substance to pass to the consumer, and a wall with an outer surface and an inner surface that define an internal space. Various embodiments of an aerosol source (or cartridge) element are described in US Pat. No. 9,078,473 to Worm et al., which is incorporated herein by reference in its entirety.

[0229] In addition to the disposable device, the disclosure may further be characterized as providing a separate control housing for use in a reusable smoking article or a reusable pharmaceutical delivery article. In particular embodiments, the control housing may generally be a housing having a receiving end (which may include an open end receiving chamber) for receiving the heated end of a separately provided aerosol source element. The control housing may also include an electrical power source that provides power to an electrical heating element, which may be a component of the control housing or may be included in an aerosol source element to be used with the control unit. For example, in some embodiments, an electrical source may power one or more heating units, which in some embodiments may be a conductive heating source and/or an inductive heating source. In some embodiments, one or more heating units may be independent and/or may be separate from one or more other heating units. Thus, in some embodiments, one or more conductive heating units may be provided. In some embodiments, one or more inductive heating units may be provided. In still other embodiments, one or more conductive heating units and one or more inductive heating units may be provided. In various embodiments, the control housing may also include additional components, including a source of electrical power (e.g., a battery), components for causing current to flow into the heating element, and components for regulating such current flow to maintain a desired temperature for a desired period. time and/or cause current to cycle or stop when the desired temperature is reached or the heating element has been heated for a desired period of time. In some embodiments, the control unit may also include one or more push buttons associated with one or both of components for causing current to flow into the heating element and components for controlling such current flow. The control housing may also include one or more indicators, such as lights, indicating that the heater is heating up and/or indicating the number of puffs remaining for the aerosol source element that is used with the control housing.

[0230] Although some of the figures described herein illustrate the control housing and the aerosol source element in an operative state, it is understood that the control housing and the aerosol source element can exist as individual devices. Accordingly, any discussion herein with respect to components in combination should also be understood to refer to the control housing and aerosol source element as individual and separate components.

[0231] In another aspect, the present invention may be directed to kits that provide a variety of components, as described herein. For example, the kit may include a control housing with one or more aerosol source elements. The kit may also include a control housing with one or more charging components. The kit may also include a control housing with one or more batteries. The kit may also include a control housing with one or more aerosol source elements and one or more charging components and/or one or more batteries. In additional embodiments, the kit may comprise a plurality of aerosol source elements. The kit may also contain a plurality of aerosol source elements and one or more batteries and/or charging components. In the above embodiments, the aerosol source elements or control housings may be provided with a heating element included therein. The kits of the invention may also include a case (or other packaging, carrying or storage component) that houses one or more additional kit components. The case can be a reusable hard or soft container. Additionally, the case may simply be a box or other packaging structure.

[0232] Many modifications and other embodiments of the present invention will be apparent to one skilled in the art to which this invention relates using the disclosures set forth in the foregoing description and accompanying drawings. Thus, it is to be understood that the invention is not limited to the specific embodiments disclosed herein and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are used herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims (35)

1. An aerosol generating substrate for use in an aerosol source element, comprising: fibrous filler material; aerosol-forming material; And many heat-conducting components; wherein said substrate is first formed in the form of a substrate sheet, and the thermally conductive components are part of said substrate sheet, and wherein the backing sheet is subsequently cut into a plurality of pieces, wherein the plurality of mixed pieces of said plurality of pieces comprises said backing, and also comprising an outer wrapping sheet configured to wrap around a substrate, said outer wrapping sheet including a plurality of thermally conductive components comprising a pattern of stripes formed on a surface of the outer wrapping sheet. 2. The aerosol generating substrate according to claim 1, wherein the substrate sheet further comprises a binder material. 3. The aerosol generating substrate according to claim 1, wherein the thermally conductive components are included in the substrate sheet. 4. The aerosol-generating substrate according to claim 1, wherein the thermally conductive components are formed on the surface of the substrate sheet. 5. The aerosol generating substrate according to claim 1, wherein the form of the thermally conductive components comprises at least one of the following: granular form, powder form, fibrous form, mesh form and fibrous fabric form. 6. The aerosol generating substrate according to claim 1, wherein the material of the thermally conductive components comprises at least one of a metal material, a metal alloy material, a ceramic material, a carbon material, and a polymer fibrous material coated with the metal material. 7. The aerosol-generating substrate according to claim 4, in which the heat-conducting components are formed in the form of a segmented pattern. 8. The aerosol generating substrate of claim 7, wherein the segmented pattern is created using at least one of printing, layering, stitching, and selective adhesion. 9. The aerosol generating substrate of claim 1, wherein the plurality of thermally conductive components comprise at least one of a metal mesh layer material and a metal fiber fabric layer material. 10. The aerosol generating substrate of claim 1, wherein the fibrous filler material comprises at least one of tobacco material and tobacco-derived material. 11. The aerosol generating substrate according to claim 1, wherein the fibrous filler material comprises a non-tobacco material. 12. The aerosol generating substrate according to claim 7, wherein the segmented pattern is created using a masking pattern. 13. An aerosol source element for use with an aerosol delivery device, comprising: a support part containing: fibrous filler material; aerosol-forming material; And many heat-conducting components; wherein the substrate portion is formed from a plurality of mixed pieces cut from the original substrate sheet formed by a fibrous filler material, an aerosol-forming material, and a plurality of thermally conductive constituents, wherein the thermally conductive components are included in said original substrate sheet, and also comprising an outer wrapping sheet configured to be wrapped around a backing portion, said outer wrapping sheet including a plurality of thermally conductive components comprising a pattern of stripes formed on a surface of the outer wrapping sheet. 14. The aerosol source element according to claim 13, wherein the support portion also contains a binder material. 15. The aerosol source element of claim 13, wherein the form of the thermally conductive constituents in the original backing sheet comprises at least one of granular form, powder form, fibrous form, mesh form, and fibrous fabric form. 16. The aerosol source element of claim 13, wherein the material of the thermally conductive constituents in the original substrate sheet comprises at least one of a metal material, a metal alloy material, a ceramic material, a carbon material, and a polymeric fibrous material coated with the metal material. 17. The aerosol source element of claim 13, wherein the plurality of thermally conductive components comprise at least one of a metal mesh layer material and a metal fiber fabric layer material. 18. The aerosol source element of claim 13, wherein the fibrous filler material of the original backing sheet comprises at least one of tobacco material and tobacco-derived material. 19. The aerosol source element of claim 13, wherein the fibrous filler material of the parent backing sheet comprises a non-tobacco material. 20. The aerosol source element of claim 13, wherein the form of the thermally conductive components of the outer wrapping sheet comprises at least one of granular form, powder form, fibrous form, mesh form, and fibrous fabric form. 21. The aerosol source element of claim 13, wherein the material of the thermally conductive constituents of the outer wrapping sheet comprises at least one of a metal material, a metal alloy material, a ceramic material, a carbon material, and a polymeric fibrous material coated with the metal material. 22. An element in the form of an aerosol source according to claim 13, in which the plurality of heat-conducting components contain a resonant receiver configured to indicate the presence of alternating current when exposed to an alternating magnetic field from the resonant transmitter.