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

Abstract

The invention relates to substrates comprising a support at least partially coated with an aerosol-generating material formed by drying a precursor material whilst in contact with the support, the precursor material comprising an extract from a flavour- and/or active-containing plant material and optionally an aerosol-former material. The substrates may be used to generate an aerosol. For example, the substrates may be used in combustible or non-combustible aerosol-provision systems. The invention also relates to aerosol-provision systems comprising the substrates, and methods of providing a substrate.

1 . A substrate comprising a support at least partially coated with an aerosol-generating material formed by drying a precursor material whilst in contact with the support, the precursor material comprising an extract from a flavour- and/or active-containing plant material. 
     
     
         2 . A substrate as claimed in  claim 1 , wherein the support comprises one or more selected from the group consisting of: paper, card, paperboard, cardboard, reconstituted material, a plastics material, a ceramic material, activated carbon, glass, a sintered material, a composite material, a plant-derived material, a fabric or fleece, a fibrous tow, a metal, or a metal alloy. 
     
     
         3 . A substrate as claimed in  claim 1 , wherein support comprises a heating material. 
     
     
         4 . A substrate as claimed in  claim 1 , wherein the aerosol-generating material covers at least a portion of a surface of the support. 
     
     
         5 . A substrate as claimed in  claim 1 , wherein a plurality of discrete portions of the aerosol-generating material are provided on the support. 
     
     
         6 . A substrate as claimed in  claim 1 , wherein the substrate does not include a binder applied to adhere the aerosol-generating material to the support. 
     
     
         7 . A substrate as claimed in  claim 1 , wherein the aerosol-generating material further comprises an aerosol-former material. 
     
     
         8 . A substrate as claimed in  claim 1 , the precursor material comprising from about 10 to about 95% by weight extract from a flavour- or active-containing plant material. 
     
     
         9 . A substrate as claimed in  claim 1 , the precursor material comprising from about 1 to about 36 wt % aerosol-former material. 
     
     
         10 . A substrate as claimed in  claim 1 , the precursor material comprising from 0 to about 40% by weight of an excipient. 
     
     
         11 . A substrate as claimed in  claim 1 , the aerosol-generating material comprising from about 45 to about 99% by weight dried extract from the flavour- or active-containing plant material. 
     
     
         12 . A substrate as claimed in  claim 1 , the aerosol-generating material comprising from about 1 to about 34% by weight aerosol-former material. 
     
     
         13 . A substrate as claimed in  claim 1 , the aerosol-generating material comprising from 0 to about 25% by weight of an excipient. 
     
     
         14 . A substrate as claimed in  claim 1 , wherein the plant material is selected from the group consisting of tobacco,  eucalyptus , star anise, cocoa and hemp. 
     
     
         15 . A substrate as claimed in  claim 1 , wherein the extract from a flavour- or active-containing plant material is an aqueous extract. 
     
     
         16 . A substrate as claimed in  claim 1 , wherein the extract from a flavour- or active-containing plant material is an aqueous tobacco extract. 
     
     
         17 . A substrate as claimed in  claim 1 , the aerosol-generating material comprising from about 40 to about 99% by weight tobacco solids. 
     
     
         18 . A substrate as claimed in  claim 1 , the aerosol-generating material having a water content of no more than about 5% (calculated on a wet weight basis). 
     
     
         19 . A substrate as claimed in  claim 1 , comprising a moisture impermeable coating surrounding the aerosol-generating material. 
     
     
         20 . A substrate as claimed in  claim 1 , comprising a sorbent material. 
     
     
         21 . A substrate as claimed in  claim 1  for use in an aerosol provision system. 
     
     
         22 . An article comprising a substrate comprising a support at least partially coated with a dried extract from a flavour- and/or active-containing plant material. 
     
     
         23 . An article wherein the article comprises or consists of a substrate as claimed in  claim 1 . 
     
     
         24 . A non-combustible aerosol-provision system comprising a substrate as claimed in  claim 1 . 
     
     
         25 . A method for providing a substrate comprising:
 contacting a support with a precursor material comprising an extract from a flavour- and/or active-containing plant material; and   drying the precursor material to form a coating of an aerosol generating material on the support.   
     
     
         26 . A method as claimed in  claim 25 , wherein the precursor material is dried by freeze-drying, infrared heating, steam heating, microwave heating or air-drying. 
     
     
         27 . A method as claimed in  claim 25 , wherein a moisture-impermeable coating is applied to the aerosol-generating material. 
     
     
         28 . A method as claimed in  claim 25 , wherein a sorbent is added to the coating of aerosol-generating material.