Aerosol-Generating Substrates and Encapsulated Flavorants

This application claims the benefit of U.S. Provisional Application No. 63/654,376, filed on May 31, 2024. The entire disclosure of the above application is incorporated herein by reference.

The present disclosure relates to aerosol-generating substrates and capsules including the same, such as for use in aerosol-generating devices, configured to generate an aerosol without involving a substantial pyrolysis of an aerosol-forming substrate.

Some electronic devices are configured to heat an aerosol-forming substrate, such as a plant material, to a temperature that is sufficient to release constituents of the plant material while keeping the temperature below a combustion point of the plant material so as to avoid any substantial pyrolysis of the plant material. Such devices may be referred to as aerosol-generating devices (e.g., heated tobacco or heated tobacco product aerosol-generating devices), and the plant material heated may be tobacco and/or. In some instances, the plant material may be introduced directly into a heating chamber of an aerosol-generating device. In other instances, the plant material may be pre-packaged in individual containers to facilitate insertion and removal from an aerosol-generating device.

At least one example embodiment relates to an aerosol-forming substrate for an aerosol-generating device.

In at least one example embodiment, the aerosol-forming substrate has a first section and a second section and includes a plurality of aerosol-forming compounds dispersed therewithin. The plurality of aerosol-forming compounds may include a first aerosol-forming compound having a first aerosolization temperature and a second aerosol-forming compound having a second aerosolization temperature that is different from the first aerosolization temperature. The first aerosolizable compound may be dispersed at a first concentration in the first section and at a second concentration different from the first concentration in the second section. The second aerosol-forming compound may be dispersed at a first concentration in the first section and at a second concentration different from the first concentration in the second section.

In at least one example embodiment, the first section may surround at least a portion of the second section.

In at least one example embodiment, the second section may be downstream from the first section.

In at least one example embodiment, the plurality of aerosol-forming compounds may include an aerosol former, a solvent, an active ingredient, a pH-adjustor, a flavorant, a thermal conductivity modifier, or any combination thereof.

In at least one example embodiment, the aerosol former and solvent may be independently selected from water, propylene glycol, glycerol, ethanol, 2-propanol, butanediol, or any combination thereof.

In at least one example embodiment, the active ingredient may include nicotine, nicotine salt, nicotine solution, encapsulated nicotine, and the combination of thereof.

In at least one example embodiment, the nicotine salt may be formed between nicotine and citrate, monotartrate, bitartrate, bitartrate dihydrate, salicylate, sulfate, bisulfate, phosphate, acid phosphate, acetate, lactate, succinate, maleate, fumarate, gluconate, saccharate, benzoate, methanesulfonate, hydrochloride, hydrobromide, hydroiodide, or any combination thereof.

In at least one example embodiment, the active ingredient may include 8-tetrahydrocannabinol (8-THC), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), tetrahydrocannabivarin (THCV), cannabidiol (CBD), cannabidiolic acid (CBDA), cannabinol (CBN), cannabichromene (CBC), cannabigerol (CBG), or any combination thereof.

In at least one example embodiment, the pH-adjustor may include pyruvic acid, formic acid, oxalic acid, glycolic acid, acetic acid, isovaleric acid, valeric acid, propionic acid, octanoic acid, lactic acid, levulinic acid, sorbic acid, malic acid, tartaric acid, succinic acid, citric acid, benzoic acid, oleic acid, aconitic acid, butyric acid, cinnamic acid, decanoic acid, 3,7-dimethyl-6-octenoic acid, 1-glutamic acid, heptanoic acid, hexanoic acid, 3-hexenoic acid, trans-2-hexenoic acid, isobutyric acid, lauric acid, 2-methylbutyric acid, 2-methylvaleric acid, myristic acid, nonanoic acid, palmitic acid, pentenoic acid, phenylacetic acid, 3-phenylpropionic acid, hydrochloric acid, phosphoric acid, sulfuric acid, ammonia, or any combination thereof.

In at least one example embodiment, the flavorant may include menthol, peppermint, spearmint, wintergreen, menthol, cinnamon, chocolate, vanillin, licorice, clove, anise, sandalwood, geranium, rose oil, vanilla, lemon oil,, fennel, ginger, ethyl acetate, isoamyl acetate, propyl isobutyrate, isobutyl butyrate, ethyl butyrate, ethyl valerate, benzyl formate, limonene, cymene, pinene, linalool, geraniol, citronellol, citral, orange oil, coriander oil, borneol, fruit extract, coffee, tea, cacao, mint, pomegranate, acai, raspberry, blueberry, strawberry, boysenberry, cranberry, bourbon, scotch, whiskey, cognac,, lavender, apple, peach, pear, cherry, plum, orange, lime, lychee, grape, grapefruit, butter, rum, coconut, almond, pecan, walnut, hazelnut, french vanilla, macadamia, sugar cane, maple, cassis, caramel, banana, malt, espresso, kahlua, white chocolate, cinnamon, clove, cilantro, basil, oregano, garlic, mustard, nutmeg, rosemary, thyme, tarragon, dill, sage, anise, fennel, methyl salicylate, linalool, jasmine, coffee, olive oil, sesame oil, sunflower oil, bergamot oil, geranium oil, lemon oil, ginger oil, balsamic vinegar, rice wine vinegar, red wine vinegar, allspice, pimento, mango, soursop, sweetsop, naseberry, sorrel, terpenes, or any combination thereof.

In at least one example embodiment, the terpenes may include 8-myrcene, 8-caryophyllene, d-limonene, linalool, pulegone, 1,8-cineole, α-pinene, α-terpineol, termine-4-ol, p-cymene, or any combination thereof.

In at least one example embodiment, the thermal conductivity modifier may include metal particles, metal granules, sheet metal slices, water, carbon fibers, graphene flakes, ceramic particles, or any combination thereof.

In at least one example embodiment, the aerosol-forming substrate may further include a tobacco material.

In at least one example embodiment, the tobacco material may include tobacco lamina, a processed tobacco material, ground tobacco, processed tobacco stems, a reconstituted tobacco material, or any combination thereof.

In at least one example embodiment, at least a portion of the plurality of aerosol-forming compounds may be surrounded by an encapsulating material.

In at least one example embodiment, one of the first and second aerosol-forming compounds may include the encapsulating material.

In at least one example embodiment, the first aerosol-forming compound may include a first encapsulating material having the first aerosolization temperature and the second aerosol-forming compound may include a second encapsulating material having the second aerosolization temperature.

In at least one example embodiment, the encapsulating material may include pectin, gelatin, sodium alginate, maltodextrin, pullulan, xanthan, gum acacia, hydroxypropylmethyl cellulose, sodium carboxy methyl cellulose, methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose, polyethylene oxide, polyvinyl alcohol, polyvinyl pyrrolidone, polyethylene glycol, polyvinyl caprolactam, polyvinyl acetate, starch, starch-derivatives, or any combination thereof.

At least one example embodiment relates to a capsule for an aerosol-generating device.

In at least one example embodiment, the capsule includes an aerosol-forming substrate having a first section and a second section and a plurality of aerosol-forming compounds dispersed within the aerosol-forming substrate, where the plurality of aerosol-forming compound includes a first aerosol-forming compound having a first aerosolization temperature and a second aerosol-forming compound having a second aerosolization temperature that is different from the first aerosolization temperature. The first aerosol-forming compound may be dispersed at a first concentration at the first section and at a second concentration different from the first concentration at the second section. The second aerosol-forming compound may be dispersed at a first concentration at the first section and at a second concentration different from the first concentration at the second section.

In at least one example embodiment, the capsule may further include a heater configured to heat the aerosol-forming substrate to generate an aerosol.

In at least one example embodiment, the first section may be closer to the heater than the second section.

In at least one example embodiment, the capsule may further include a housing that encompasses the aerosol-forming substrate and heater.

In at least one example embodiment, the first section may surround at least a portion of the second section.

In at least one example embodiment, the second section may be downstream from the first section.

In at least one example embodiment, the plurality of aerosol-forming compounds may include an aerosol former, a solvent, an active ingredient, a pH-adjustor, a flavorant, a thermal conductivity modifier, or any combination thereof.

In at least one example embodiment, the aerosol former and solvent may be independently selected from water, propylene glycol, glycerol, ethanol, 2-propanol, butanediol, or any combination thereof.

In at least one example embodiment, the active ingredient may include nicotine, nicotine salt, nicotine solution, encapsulated nicotine, and the combination of thereof.

In at least one example embodiment, the nicotine salt may be formed between nicotine and citrate, monotartrate, bitartrate, bitartrate dihydrate, salicylate, sulfate, bisulfate, phosphate, acid phosphate, acetate, lactate, succinate, maleate, fumarate, gluconate, saccharate, benzoate, methanesulfonate, hydrochloride, hydrobromide, hydroiodide, or any combination thereof.

In at least one example embodiment, the active ingredient may include 8-tetrahydrocannabinol (8-THC), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), tetrahydrocannabivarin (THCV), cannabidiol (CBD), cannabidiolic acid (CBDA), cannabinol (CBN), cannabichromene (CBC), cannabigerol (CBG), or any combination thereof.

In at least one example embodiment, the pH-adjustor may include pyruvic acid, formic acid, oxalic acid, glycolic acid, acetic acid, isovaleric acid, valeric acid, propionic acid, octanoic acid, lactic acid, levulinic acid, sorbic acid, malic acid, tartaric acid, succinic acid, citric acid, benzoic acid, oleic acid, aconitic acid, butyric acid, cinnamic acid, decanoic acid, 3,7-dimethyl-6-octenoic acid, 1-glutamic acid, heptanoic acid, hexanoic acid, 3-hexenoic acid, trans-2-hexenoic acid, isobutyric acid, lauric acid, 2-methylbutyric acid, 2-methylvaleric acid, myristic acid, nonanoic acid, palmitic acid, pentenoic acid, phenylacetic acid, 3-phenylpropionic acid, hydrochloric acid, phosphoric acid, sulfuric acid, ammonia, or any combination thereof.

In at least one example embodiment, the flavorant may include menthol, peppermint, spearmint, wintergreen, menthol, cinnamon, chocolate, vanillin, licorice, clove, anise, sandalwood, geranium, rose oil, vanilla, lemon oil,, fennel, ginger, ethyl acetate, isoamyl acetate, propyl isobutyrate, isobutyl butyrate, ethyl butyrate, ethyl valerate, benzyl formate, limonene, cymene, pinene, linalool, geraniol, citronellol, citral, orange oil, coriander oil, borneol, fruit extract, coffee, tea, cacao, mint, pomegranate, acai, raspberry, blueberry, strawberry, boysenberry, cranberry, bourbon, scotch, whiskey, cognac,, lavender, apple, peach, pear, cherry, plum, orange, lime, lychee, grape, grapefruit, butter, rum, coconut, almond, pecan, walnut, hazelnut, french vanilla, macadamia, sugar cane, maple, cassis, caramel, banana, malt, espresso, kahlua, white chocolate, cinnamon, clove, cilantro, basil, oregano, garlic, mustard, nutmeg, rosemary, thyme, tarragon, dill, sage, anise, fennel, methyl salicylate, linalool, jasmine, coffee, olive oil, sesame oil, sunflower oil, bergamot oil, geranium oil, lemon oil, ginger oil, balsamic vinegar, rice wine vinegar, red wine vinegar, allspice, pimento, mango, soursop, sweetsop, naseberry, sorrel, terpenes, or any combination thereof.

In at least one example embodiment, the terpenes may include 8-myrcene, 8-caryophyllene, d-limonene, linalool, pulegone, 1,8-cineole, α-pinene, α-terpineol, termine-4-ol, p-cymene, or any combination thereof.

In at least one example embodiment, the thermal conductivity modifier may include metal particles, metal granules, sheet metal slices, ceramic particles, graphene flakes, water, carbon fibers, graphene flakes, ceramic particles, or any combination thereof.

In at least one example embodiment, the aerosol-forming substrate may include a tobacco material.

In at least one example embodiment, the tobacco material may include tobacco lamina, a processed tobacco material, ground tobacco, processed tobacco stems, a reconstituted tobacco material, or any combination thereof.

In at least one example embodiment, the aerosol-forming substrate includes a tobacco substitute material.

In at least one example embodiment, the tobacco substitute material includes wood pulp, cotton, sugar beets, bran, citrus pulp fiber, switch grass, salix tea,, bamboo, hemp,, or any combination thereof.

In at least one example embodiment, at least a portion of the plurality of aerosol-forming compounds may be surrounded by an encapsulating material.

In at least one example embodiment, one of the first and second aerosol-forming compounds may include the encapsulating material.

In at least one example embodiment, the first aerosol-forming compound may include a first encapsulating material having the first aerosolization temperature and the second aerosol-forming compound may include a second encapsulating material having the second aerosolization temperature.

In at least one example embodiment, the encapsulating material may include pectin, gelatin, sodium alginate, maltodextrin, pullulan, xanthan, gum acacia, hydroxypropylmethyl cellulose, sodium carboxy methyl cellulose, methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose, polyethylene oxide, polyvinyl alcohol, polyvinyl pyrrolidone, polyethylene glycol, polyvinyl caprolactam, polyvinyl acetate, starch, starch-derivatives, or any combination thereof.

At least one example embodiment relates to a capsule for an aerosol-generating device.

In at least one example embodiment, the capsule may include an aerosol-forming substrate and a plurality of aerosol-forming compounds dispersed within the aerosol-forming substrate. The plurality of aerosol-forming compounds may include a first aerosol-forming compound having a first aerosolization temperature and a second aerosol-forming compound having a second aerosolization temperature that is different from the first aerosolization temperature. The first aerosol-forming compound and the second aerosol-forming compound may each be dispersed throughout the aerosol-forming substrate, and at least one of the first aerosol-forming compound or the second aerosol-forming compound may have a non-uniform dispersion concentration.

In at least one example embodiment, the first aerosol-forming compound may have a first non-uniform dispersion concentration, and the second aerosol-forming compound may have a second non-uniform dispersion concentration.

In at least one example embodiment, the aerosol-forming substrate may include a first section. The first section may include a first concentration of the first aerosol-forming compound and a first concentration of the second aerosol-forming compound. The first concentration of the first aerosol-forming compound may be different from the first concentration of the second aerosol-forming compound.