KR20240032911A - Thermally enhanced aerosol-forming substrate - Google Patents

Abstract

An aerosol-forming substrate for use in a heated aerosol-generating article is provided, the aerosol-forming substrate comprising a co-laminated sheet comprising a layer of an aerosol-forming material and a layer of a carbon-based thermally conductive material.

Description

Thermally enhanced aerosol-forming substrate

The present disclosure relates to aerosol-forming substrates. The present disclosure also relates to aerosol-forming substrates, aerosol-generating articles, and rods comprising aerosol-generating systems, as well as methods of making aerosol-forming substrates, rods, and aerosol-generating articles.

A typical aerosol-generating system includes an aerosol-generating device and an aerosol-generating article comprising an aerosol-forming substrate. In use, the aerosol-generating device interacts with the aerosol-generating article to heat the aerosol-forming substrate and cause the aerosol-forming substrate to release volatile compounds. These compounds are then cooled to form an aerosol that is inhaled by the user.

Known aerosol-forming substrates typically have relatively low thermal conductivity. This may be undesirable, especially in aerosol-generating systems where the blades are inserted into the aerosol-forming substrate and heated to heat the aerosol-forming substrate. This is because the low thermal conductivity of the aerosol-forming substrate can result in relatively large temperature gradients in the aerosol-forming substrate during use. This may mean that the portion of the aerosol-forming substrate located furthest from the blade does not reach high temperatures and therefore does not release as many volatile compounds as if the aerosol-forming substrate had a higher thermal conductivity. That is, the low thermal conductivity of the aerosol-forming substrate may undesirably result in low efficiency of use of the aerosol-forming substrate.

Additionally, known aerosol-forming substrates typically cannot be heated to operating temperatures by induction. This means that for induction heating, a separate susceptor element is usually required. This may increase costs. Additionally, this may lead to the same problems as described above. For example, if an inductively heated susceptor element is placed in a central location within the substrate, the portion of the aerosol-forming substrate located furthest from the susceptor element may not reach high temperatures and therefore may not emit as many volatile compounds. .

Attempts have been made to increase the thermal conductivity of aerosol-forming substrates. However, to date, these attempts have been inadequate in one or more respects.

The object of the present invention is to provide improved aerosol-forming substrates, for example aerosol-forming substrates with increased thermal conductivity. Furthermore, it is an object of the present invention to provide such an aerosol-forming substrate with increased thermal conductivity while having improved tensile strength.

According to the present disclosure, an aerosol-forming substrate is provided. Aerosol-forming substrates may be suitable for use in heated aerosol-generating articles. The aerosol-forming substrate may include co-laminated sheets. The co-laminated sheet may include a layer of aerosol-generating material. The co-laminated sheet may include a layer of carbon-based thermally conductive material.

Accordingly, according to a first aspect of the present disclosure, there is provided an aerosol-forming substrate for use in a heated aerosol-generating article, the aerosol-forming substrate comprising a co-laminated sheet comprising a layer of an aerosol-forming material and a layer of a carbon-based thermally conductive material. provided.

As used herein, the term "carbon-based thermally conductive material" refers to a material comprising carbon, such as a material comprising or consisting of one or more of graphite, expanded graphite, graphene, carbon nanotubes, and charcoal. It is used to

A layer of carbon-based thermally conductive material comprising or consisting of at least one of graphite and expanded graphite may be particularly preferred. The layer of carbon-based thermally conductive material may be referred to as a carbon material or a carbon-containing material.

Advantageously, the layer of carbon-based thermally conductive material can increase the thermal conductivity of the aerosol-forming substrate. This can provide a more uniform temperature distribution throughout the substrate during use. This may result in a greater proportion of the aerosol-forming substrate reaching a sufficiently high temperature to release volatile compounds, and thus a higher use efficiency of the aerosol-forming substrate. Alternatively or additionally, the increased thermal conductivity of the substrate may allow heaters, such as heating blades configured to heat the substrate, to operate at lower temperatures and require less power.

Advantageously, layers of carbon-based thermally conductive materials such as those listed above, particularly materials comprising graphite and expanded graphite, may have high thermal conductivity and low density, without significantly increasing the density of the aerosol-forming substrate. The thermal conductivity of an aerosol-forming substrate can be substantially improved. It may be advantageous to avoid significantly increasing the density of the aerosol-forming substrate. This is because an increase in density can increase the weight for a given volume of substrate and thus increase transport costs.

As used herein, the term 'sheet' refers to a laminated element having a width and length substantially greater than its thickness. The width of the sheet is greater than 10 mm, preferably greater than 20, 30, 40, 50, 60, 70, 80, 90, and 100 mm. The width of the sheets may be less than 300, 250, 200 or 150 millimeters. As will be described, the co-laminated sheets may be subjected to processing steps such as corrugation. In this case, the “width” of the sheet may refer to the width of the sheet before corrugation.

As used herein, the term “co-laminated sheet” refers to a single sheet formed from two or more layers of material that are tightly packed together. In particular, the co-laminated sheet includes a layer of aerosol-forming material in close contact with a layer of thermally conductive material. Close adhesion between the layer of aerosol-forming material and the layer of carbon-based thermally-conductive material means that heat can be transferred by the layer of aerosol-forming material throughout the layer of aerosol-forming material by conduction. This improves the thermal conductivity of the aerosol-forming substrate.

The layer of carbon-based thermally conductive material may have a length and width similar to or the same as the length and width of the layer of aerosol-forming material.

The layer of carbon-based thermally conductive material may be in contact with the layer of aerosol-forming material over substantially the entire surface of the thermally conductive material.

Layers of co-laminated sheets can form a single sheet.

The co-laminated sheet may include one or more layers of an aerosol-forming material. The co-laminated sheet may include one or more layers of thermally conductive material. Each layer of aerosol-forming material may be sandwiched between layers of thermally conductive material. Alternatively or additionally, each layer of thermally conductive material may be sandwiched between layers of aerosol-forming material.

The co-laminated sheet may include one or more additional layers comprising materials other than the carbon-based thermally conductive material and the aerosol-forming material.

The layer of thermally conductive material or each layer of thermally conductive material may be in the form of a film or foil. Because the film or foil is thin, only a small volume of the aerosol-forming substrate can be absorbed by the layer or layers of heat-conductive material. However, since the thermally conductive layer can be provided as a layer that can advantageously extend throughout the aerosol-forming substrate, the thermal conductivity of the substrate is improved throughout the substrate.

The layer of thermally conductive material or each layer of thermally conductive material may be flexible. The layer of aerosol-forming material or each layer of aerosol-forming material may be flexible. In this way, the co-laminated sheet can also be flexible. This can be particularly advantageous when the co-laminated sheets are gathered to form rods of aerosol-forming substrate, as described below. The corrugated co-laminated sheet preferably extends substantially along the entire length of the rod and substantially over the entire cross-sectional area of the rod.

The layer of thermally conductive material or each layer of thermally conductive material is 10, 5, 3, 2, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, 0.1, 0.09, 0.08, 0.07, 0.06, It may have a thickness of less than 0.05, 0.04, 0.03 or 0.02 millimeters.

The layer of thermally conductive material or each layer of thermally conductive material is 10 to 0.02, or 5 to 0.02, 3 to 0.02, 2 to 0.02, 1 to 0.02, 0.9 to 0.02, 0.8 to 0.02, 0.7 to 0.02, 0.6 to 0.02. , 0.5 to 0.02, 0.4 to 0.02, 0.3 to 0.02, 0.2 to 0.02, 0.1 to 0.02, 0.09 to 0.02, 0.08 to 0.02, 0.07 to 0.02, 0.06 to 0.02, 0.05 to 0.02, 0.04 to Can have a thickness of 0.02 millimeters there is.

Preferably, the layer of carbon-based thermally conductive material may comprise or consist of carbon fibers, graphite or graphene.

Even more preferably, the layer of carbon-based thermally conductive material may comprise or consist of expanded graphite.

Optionally, the layer of carbon-based thermally conductive material may include both graphite and expanded graphite.

The layer of carbon-based thermally conductive material may consist of flexible graphite or flexible graphite and expanded graphite foil or film.

The layer of carbon-based thermally conductive material can have a density that is less than or equal to the density of the aerosol-forming material.

The layer of thermally conductive material can have a density that is at least 1, 2, 5, 10, 15, 20, 25, or 30% less than the density of the aerosol-forming material.

The aerosol-forming substrate may have a density of less than 1050, 1000, 950, 900, 850, 800, 850, 800, 750, 700, or 650 kg/m3.

The aerosol-forming substrate may have a density of 500 to 900 kg/m ³ , for example 600 to 800 kg/m ³ .

The layer of carbon-based thermally conductive material may have a density of less than 3, 2, 1.8, 1.5, 1.2, 1, 0.8, 0.5, 0.2, 0.1, 0.05, 0.02 grams per cubic centimeter (g/cm ³ ).

The layer of carbon-based thermally conductive material may have a density greater than 0.01, 0.02, 0.05, 0.1, 0.2, 0.5, 0.8, 1, 1.2, 1.5 or 1.8 grams per cubic centimeter (g/cm ³ ).

The layers of carbon-based thermally conductive material are 0.01 to 3, 0.01 to 2, 0.01 to 1.8, 0.01 to 1.5, 0.01 to 1.2, 0.01 to 1, 0.01 to 0.8, 0.01 to 0.5, 0.02 to 3, 0.02 to 2, 0.02 to 1. 1.8, 0.02 to 1.5, 0.02 to 1.2, 0.02 to 1, 0.02 to 0.8, 0.02 to 0.5, 0.01 to 3, 0.05 to 2, 0.05 to 1.8, 0.05 to 1.5, 0.05 to 1.2, 0.05 to 1, 0.05 to 1.8 0.8, 0.05 to 0.5 g/cm3, 0.1 to 3, 0.1 to 2, 0.1 to 1.8, 0.1 to 1.5, 0.1 to 1.2, 0.1 to 1, 0.1 to 0.8, 0.1 to 0.5, 0.2 to 3, 0.2 to 2, 0.2 to 1.8 , 0.2 to 1.5, 0.2 to 1.2, 0.2 to 1, 0.2 to 0.8, 0.2 to 0.5, 0.5 to 3, 0.5 to 2, 0.5 to 1.8, 0.5 to 1.5, 0.5 to 1.2, 0.5 to 1, 0.5 to 0.8, 0.8 It may have a density of from 3 to 3, from 0.8 to 2, from 0.8 to 1.8, from 0.8 to 1.5, from 0.8 to 1.2, from 0.8 to 1 gram per cubic centimeter (g/cm3).

Advantageously, the use of a low density layer of thermally conductive material can result in a low density substrate. This can reduce the weight for a given volume of substrate and thus transport costs.

The layer of carbon-based thermally conductive material may have a tensile strength of greater than 1, 2, 3, 4, 5, 6, 7, 8, or 9 megapascals (MPa).

Providing an aerosol-forming substrate in the form of a co-laminated sheet comprising such layers of carbon-based thermally conductive material can advantageously increase the overall tensile strength of the substrate. Additionally, the layer of carbon-based thermally conductive material can provide support for the layered aerosol-forming material. As such, the rod of aerosol-generating substrate may not need to include an additional support layer. In some embodiments, during the manufacture of the aerosol-forming substrate, the aerosol-forming material can advantageously be cast directly onto the layer of carbon-based thermally conductive material.

The layer of carbon-based thermally conductive material may consist of a foil or film comprising at least 90%, 95%, 97%, 99%, 99.5% or 99.9% graphite or expanded graphite by weight.

The layer of carbon-based thermally conductive material may comprise or consist of a reconstituted carbon-based material, preferably a reconstituted sheet of graphite or expanded graphite, and even more preferably a reconstituted graphite or expanded graphite film or foil.

The reconstituted carbon-based material may include thermally conductive particles. Each of the thermally conductive particles may have a thermal conductivity of at least 1 watt per meter Kelvin [W/(mK)] in at least one direction at 25 degrees Celsius. Some or all of the thermally conductive particles comprise carbon, for example at least 10, 30, 50, 70, 90, 95, 98, or 99% carbon by weight. Optionally, some or all of the thermally conductive particles include one or more of graphite, expanded graphite, graphene, carbon nanotubes, and charcoal. Optionally, some or all of the thermally conductive particles are graphitic particles. Optionally, some or all of the thermally conductive particles are expanded graphite particles. Optionally, some or all of the thermally conductive particles are graphene particles. Advantageously, these materials have relatively high thermal conductivity.

The reconstituted carbon-based material may include at least 10%, 20%, 30%, 40%, 50%, 60%, or 70% by weight of thermally conductive particles. The reconstituted carbon base may contain less than 90%, 95%, or 80% by weight of thermally conductive particles.

The reconstituted carbon-based material may include an aerosol former. The reconstituted carbon-based material may include 7 to 60% by dry weight of an aerosol former.

The reconstituted carbon-based material may include fibers. The layer of reconstituted carbon-based material may include 2 to 20 weight percent fibers on a dry weight basis. Optionally, the fibers are cellulose fibers. Advantageously, cellulosic fibers are not overly costly and can increase the tensile strength of the substrate.

Optionally, each fiber has three mutually perpendicular dimensions, the largest of the three dimensions being at least 1.5, 2, 3, 5, 10, or 20 times larger than the smallest of the three dimensions. Optionally, each fiber has three mutually perpendicular dimensions, the largest of the three dimensions being at least 1.5, 2, 3, 5, 10, or 20 times larger than the second largest of the three dimensions.

The reconstituted carbon-based material may include a binder. The reconstituted carbon-based material may include 2 to 10 weight percent binder on a dry weight basis. Optionally, the substrate comprises at least 4, 6, or 8 weight percent binder, on a dry weight basis. Optionally, the substrate comprises up to 8, 6, or 4 weight percent binder on a dry weight basis. Optionally, the substrate comprises 4 to 10, 6 to 10, 8 to 10, 2 to 8, 4 to 8, 6 to 8, 2 to 6, 4 to 6, 2 to 4 weight percent binder, on a dry weight basis. do. It may be particularly desirable for the substrate to comprise from 2.1 to 10% by weight of binder, on a dry weight basis.

Suitable binders are well known in the art and include natural pectins such as fruit, citrus or tobacco pectin; guar gums such as hydroxyethyl guar and hydroxypropyl guar; locust bean gum, such as hydroxyethyl and hydroxypropyl locust bean gum; alginate; Starches, such as engineered or derived starches; cellulose such as methyl, ethyl, ethylhydroxymethyl and carboxymethyl cellulose; tamarind gum; dextran; pullon; konjac flour; Includes, but is not limited to, xanthan gum. It may be particularly desirable for the binder to be or comprise guar. It may be particularly preferred if the binder comprises or consists of one or more of carboxymethyl cellulose or hydroxypropyl cellulose or gums such as guar gum.

Optionally, the thermally conductive particles are distributed substantially homogeneously throughout the layer of thermally conductive material. Optionally, the aerosol former is distributed substantially homogeneously throughout the layer of thermally conductive material. Optionally, the fibers are distributed substantially homogeneously throughout the layer of thermally conductive material. Optionally, the binder is distributed substantially homogeneously throughout the layer of thermally conductive material. Advantageously, a homogeneous distribution of the components of the substrate can cause the substrate to have more spatially uniform properties. For example, substantially homogeneously distributed thermally conductive particles can cause a substrate to have substantially uniform thermal conductivity. As another example, substantially homogeneously distributed binders or fibers can cause a substrate to have a substantially uniform tensile strength.

Advantageously, one or both of the fibers and binder can increase the tensile strength of the reconstituted carbon-based material. Increased tensile strength may allow for the production of sheets of reconstituted carbon-based material that do not tear easily. Increased tensile strength may allow production of reconstituted carbon-based materials using existing production machinery.

The thermally conductive particles can each have a “particle size.” The meaning of the term “particle size” and methods of measuring particle size are explained later.

Thermally conductive particles can be characterized by their particle size distribution. The particle size distribution may have several D10, D50 and D90 particle sizes. The number D10 particle size is defined as having 10% of the particles having a particle size of less than or equal to the number D10 particle size. Similarly, the number D50 particle size is defined such that 50% of the particles have a particle size of less than or equal to the number D50 particle size. Accordingly, the number D50 particle size may be referred to as the median particle size. The number D90 particle size is defined as having 90% of the particles having a particle size of less than or equal to the number D90 particle size. Therefore, if there are 1,000 particles in the distribution and the particles are sorted in ascending order by particle size, the D10 particle size is expected to be approximately equal to the particle size of the 100th particle, and the D50 particle size is expected to be approximately equal to the particle size of the 500th particle. Expected to be the same, the D90 particle size would be expected to be approximately the same as the particle size of the 900th particle.

The particle size distribution may have volumetric D10, D50 and D90 particle sizes. Volume D10 particle size is defined as 10% of the sum of the volumes of all particles equal to the sum of the volumes of particles having a particle size less than or equal to the volume D10 particle size. Similarly, the volumetric D50 particle size is defined as 50% of the sum of the volumes of all particles equal to the sum of the volumes of particles having a particle size less than or equal to the volumetric D50 particle size. And, the volume D90 particle size is defined as 90% of the sum of the volumes of all particles corresponding to the sum of the volumes of particles having a particle size less than or equal to the volume D90 particle size.

Optionally, the thermally conductive particles have a particle size distribution having a number D10 particle size, wherein the number D10 particle size is at least 0.1, 0.2, 0.5, 1, 2, 5, 10, 20, 50, 100, 200, or 500 microns. .

Optionally, the thermally conductive particles have a particle size distribution having a number D10 particle size, wherein the number D10 particle size is no greater than 1,000, 500, 200, 100, 50, 20, 10, 5, 2, 1, 0.5, or 0.2 microns. .

A compromise must be made when determining particle size. Larger thermally conductive particles can advantageously increase the thermal conductivity of the reconstituted carbon-based material, such that the aerosol-forming substrate comprising the reconstituted carbon-based material has more than smaller thermally conductive particles. However, larger thermally conductive particles can reduce the space available for aerosol-forming materials within the substrate.

Optionally, the thermally conductive particles have a particle size distribution having a number D50 particle size, wherein the number D50 particle size is at least 0.1, 0.2, 0.5, 1, 2, 5, 10, 20, 50, 100, 200, or 500 microns. .

Optionally, the thermally conductive particles have a particle size distribution having a number D50 particle size, wherein the number D50 particle size is less than or equal to 1,000, 500, 200, 100, 50, 20, 10, 5, 2, 1, 0.5, or 0.2 microns. .

Optionally, the thermally conductive particles have a particle size distribution having a number D90 particle size, wherein the number D90 particle size is at least 0.1, 0.2, 0.5, 1, 2, 5, 10, 20, 50, 100, 200, or 500 microns. .

Optionally, the thermally conductive particles have a particle size distribution having a number D90 particle size, wherein the number D90 particle size is less than or equal to 1,000, 500, 200, 100, 50, 20, 10, 5, 2, 1, 0.5, or 0.2 microns. .

Optionally, the thermally conductive particles have a particle size distribution having a number D10 particle size and a number D90 particle size, wherein the number D90 particle size is no more than 50, 40, 30, 20, 10, or 5 times the number D10 particle size.

Optionally, the thermally conductive particles have a particle size distribution having a number D10 particle size and a number D90 particle size, wherein the number D90 particle size is at least 1.5, 2, 3, 5, 10, or 20 times the number D10 particle size.

A compromise must be made regarding particle size distribution. For example, a narrower particle size distribution characterized by a smaller ratio between D90 and D10 particle sizes can advantageously provide more uniform thermal conductivity throughout the reconstituted carbon-based material. This is because there is little variation in particle size at different locations within the substrate. This may advantageously allow more efficient use of the aerosol-forming material throughout the aerosol-forming substrate. However, tighter particle size distributions can disadvantageously be more difficult and expensive to achieve. The inventors have found that the particle size distribution described above can provide an optimal compromise between these two factors.

Optionally, the thermally conductive particles have a particle size distribution having a volume D10 particle size, wherein the volume D10 particle size is at least 0.1, 0.2, 0.5, 1, 2, 5, 10, 20, 50, 100, 200, or 500 microns. .

Optionally, the thermally conductive particles have a particle size distribution having a volume D10 particle size, wherein the volume D10 particle size is less than or equal to 1,000, 500, 200, 100, 50, 20, 10, 5, 2, 1, 0.5, or 0.2 microns. .

Optionally, the thermally conductive particles have a particle size distribution having a volume D50 particle size, wherein the volume D50 particle size is at least 0.1, 0.2, 0.5, 1, 2, 5, 10, 20, 50, 100, 200, or 500 microns. .

Optionally, the thermally conductive particles have a particle size distribution having a volumetric D50 particle size, wherein the volumetric D50 particle size is less than or equal to 1,000, 500, 200, 100, 50, 20, 10, 5, 2, 1, 0.5, or 0.2 microns. .

Optionally, the thermally conductive particles have a particle size distribution having a volumetric D90 particle size, wherein the volumetric D90 particle size is at least 0.1, 0.2, 0.5, 1, 2, 5, 10, 20, 50, 100, 200, or 500 microns. .

Optionally, the thermally conductive particles have a particle size distribution having a volumetric D90 particle size, wherein the volumetric D90 particle size is less than or equal to 1,000, 500, 200, 100, 50, 20, 10, 5, 2, 1, 0.5, or 0.2 microns. .

It may be particularly desirable for the thermally conductive particles to have a particle size distribution with a volume D10 particle size of 1 to 20 microns. Alternatively or additionally, it may be particularly desirable for the thermally conductive particles to have a particle size distribution with a volumetric D90 particle size of 50 to 300 microns, or 50 to 200 microns.

Optionally, the thermally conductive particles have a particle size distribution having a volume D10 particle size and a volume D90 particle size, wherein the volume D90 particle size is no more than 50, 40, 30, 20, 10, or 5 times the volume D10 particle size.

Optionally, the thermally conductive particles have a particle size distribution having a volume D10 particle size and a volume D90 particle size, wherein the volume D90 particle size is at least 1.5, 2, 3, 5, 10, or 20 times the volume D10 particle size.

As mentioned above, compromises must be made regarding particle size distribution, and the inventors have found that the above particle size distribution may provide an optimal compromise.

Optionally, each of the thermally conductive particles has a particle size of at least 0.01, 0.1, 0.2, 0.5, 1, 2, 5, 10, 20, 50, 100, 200, or 500 microns. Optionally, each of the thermally conductive particles has a particle size of no more than 1,000, 500, 300, 200, 100, 50, 20, 10, 5, 2, 1, 0.5, or 0.2 microns. It may be particularly desirable for each thermally conductive particle to have a particle size of at least 1 micron. Alternatively or additionally, it may be particularly desirable for each of the thermally conductive particles to have a particle size of 300 microns or less. Particles smaller than 1 micron can be difficult to handle during manufacturing. Particles larger than 300 microns can take up a rather large amount of space within the substrate that can be used for aerosol-forming materials. Accordingly, it may be particularly advantageous for each of the thermally conductive particles to have a particle size of at least 1 micron, or a particle size of 300 microns or less, or both.

Optionally, each thermally conductive particle has three mutually perpendicular dimensions, the largest of the three dimensions being no more than 10, 8, 5, 3, or 2 times larger than the smallest of the three dimensions. Optionally, each thermally conductive particle has three mutually perpendicular dimensions, the largest of the three dimensions being no more than 10, 8, 5, 3, or 2 times larger than the second largest of the three dimensions. Optionally, each thermally conductive particle is substantially spherical. Advantageously, the orientation of the substantially spherical particles may not affect the thermal conductivity of the substrate as much as the orientation of the non-spherical particles. Therefore, the use of more spherical particles may result in less variability between different substrates where the orientation of the particles is not controlled. Additionally, substantially spherical particles may be easier to characterize.

Optionally, the thermally conductive particles include at least 10, 20, 50, 100, 200, 500, or 1000 particles. Advantageously, a greater number of particles in the aerosol-forming substrate allows the thermal conductivity of the substrate to be more uniform.

Optionally, the substrate comprises at least 20, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80 or 85% by weight of thermally conductive particles, on a dry weight basis. Optionally, the substrate comprises no more than 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, or 15 weight percent thermally conductive particles on a dry weight basis. Optionally, the substrate has, by dry weight, 10 to 90, 20 to 90, 30 to 90, 40 to 90, 50 to 90, 60 to 90, 70 to 90, 80 to 90, 10 to 80, 20 to 80 , 30 to 80, 40 to 80, 50 to 80, 60 to 80, 70 to 80, 10 to 70, 20 to 70, 30 to 70, 40 to 70, 50 to 70, 60 to 70, 10 to 60, 20 to 60, 30 to 60, 40 to 60, 50 to 60, 10 to 50, 20 to 50, 30 to 50, 40 to 50, 10 to 40, 20 to 40, 30 to 40, 10 to 30, 20 to 30 , or 10 to 20% by weight of thermally conductive particles. It may be particularly preferred for the substrate to comprise from 50 to 90, or more preferably from 60 to 90, or even more preferably from 65 to 85% by weight of thermally conductive particles, on a dry weight basis.

Inclusions should be made in relation to the weight percent of thermally conductive particles in the substrate. Increasing the weight percent of particles in an aerosol-forming substrate can advantageously increase the thermal conductivity of the substrate. However, increasing the weight percent of particles in an aerosol-forming substrate can also reduce the available space for one or more of the aerosol former, binder, and fibers, thereby forming less aerosol or having a substrate with less tensile strength. may result in

The layer of carbon-based thermally conductive material does not contain tobacco. The layer of carbon-based thermally conductive material may not contain nicotine.

The layer of carbon-based thermally conductive material may be formed by a casting process.

Co-laminated sheets may include or have the form of corrugated sheets. The carbon-based thermally conductive material may have sufficient tensile strength to withstand the wrinkling process while supporting the aerosol-forming material layer.

The layer of carbon-based thermally conductive material may have a thermal conductivity greater than 1, 2, 5, 10, 20, 50, 100, 200, 500, 1000 or 1500 W/(mK). Thermal conductivity may be thermal conductivity when measured at 25°C.

The layer of carbon-based thermally conductive material may exhibit anisotropic thermal conductivity. The layer of carbon-based thermally conductive material may lie within or define a plane. The thermal conductivity of the in-plane carbon-based thermally conductive material layer may be greater than 1, 2, 5, 10, 20, 50, 100, 200, 500, 1000 or 1500 W/mK. Thermal conductivity may be thermal conductivity when measured at 25°C.

Advantageously, increasing the thermal conductivity of the thermally conductive material layer can increase the thermal conductivity of the aerosol-forming substrate.

The expanded graphite may have a density of less than 2, 1.8, 1.5, 1.2, 1, 0.8, or 0.5, 0.2, 0.1, 0.05, or 0.02 grams per cubic centimeter (g/cm ³ ).

Expanded graphite may have a density greater than 0.01, 0.02, 0.05, 0.1, 0.2, 0.5, 0.8, 1, 1.2, 1.5 or 1.8 grams per cubic centimeter (g/cm ³ ).

Expanded graphite is 0.01 to 3, 0.01 to 2, 0.01 to 1.8, 0.01 to 1.5, 0.01 to 1.2, 0.01 to 1, 0.01 to 0.8, 0.01 to 0.5, 0.02 to 3, 0.02 to 2, 0.02 to 1.8, 0.02 to 1. 5 , 0.02 to 1.2, 0.02 to 1, 0.02 to 0.8, 0.02 to 0.5, 0.01 to 3, 0.05 to 2, 0.05 to 1.8, 0.05 to 1.5, 0.05 to 1.2, 0.05 to 1, 0.05 to 0.8, 0.05 to 0. 5g/ cm ³ , 0.1 to 3, 0.1 to 2, 0.1 to 1.8, 0.1 to 1.5, 0.1 to 1.2, 0.1 to 1, 0.1 to 0.8, 0.1 to 0.5, 0.2 to 3, 0.2 to 2, 0.2 to 1.8, 0.2 to 1.5 , 0.2 to 1.2, 0.2 to 1, 0.2 to 0.8, 0.2 to 0.5, 0.5 to 3, 0.5 to 2, 0.5 to 1.8, 0.5 to 1.5, 0.5 to 1.2, 0.5 to 1, 0.5 to 0.8, 0.8 to 3, 0.8 It may have a density of grams per cubic centimeter (g/cm ³ ) between 2, 0.8 and 1.8, 0.8 and 1.5, 0.8 and 1.2, and 0.8 and 1.

The layer of carbon-based thermally conductive material may include greater than 10, 30, 50, 70, 80, 90, 95, 98, 99, 99.5, or 99.9 weight percent carbon. The layer of carbon-based thermally conductive material may be made of carbon except for trace impurities.

The layer of carbon-based thermally conductive material may constitute up to 90, 80, 70, 60, 50, 20, 10, or 5 weight percent of the aerosol-forming substrate. The layer of carbon-based thermally conductive material may constitute at least 0.1, 0.2, 0.5, 1, 2, 3, 5, 10, 20, 30, 40, or 50% by weight of the aerosol-forming substrate. The layer of carbon-based thermally conductive material is 20 to 90, 20 to 90, 30 to 90, 40 to 90, 20 to 80, 30 to 80, 40 to 80, 20 to 70, 30 to 70, 40 to 40 of the aerosol-forming substrate. It may constitute 70, 20 to 60, 30 to 60, 40 to 60, 20 to 50, and 30 to 50% by weight.

Advantageously, the inventors have found that these weight percentages provide an optimal compromise between increasing the thermal conductivity of the aerosol-forming substrate and maintaining sufficient aerosol-forming material to form an appropriate amount of aerosol.

The layer of aerosol-forming material may have a thermal conductivity of 0.1 W/mK to 0.2 W/mK. This may be the case where the aerosol forming material is standard homogenized tobacco. Accordingly, in some embodiments, the aerosol-forming material may have a thermal conductivity of less than 0.2 W/mK, e.g., as measured at 25°C, and the layer of carbon-based thermally conductive material may have a thermal conductivity of less than 0.2 W/mK, e.g., as measured at 25°C. When measured, it may have a thermal conductivity greater than 0.22 W/mK, preferably even greater. A layer of carbon-based thermally conductive material can have a thermal conductivity as high as 1700 W/mK, for example as found in commercial graphite foil along its planar direction.

These thermal conductivities can be measured when the moisture content of the material is 0 to 20, or 5 to 15, for example about 10%. This thermal conductivity can be measured when the material contains 0 to 20, or 5 to 15, for example about 10% water by weight. The moisture or moisture content of a substance can be measured using titrimetric methods. The moisture or moisture content of a substance can be measured using the Karl Fisher method.

The aerosol-forming material is preferably configured to generate an aerosol when heated, for example to a temperature of 120 degrees Celsius to 395 degrees Celsius. In some embodiments, the layer of carbon-based thermally conductive material is not configured to generate aerosols when heated, for example, to a temperature of 120 degrees Celsius to 350 degrees Celsius. Accordingly, in these embodiments, the layer of carbon-based thermally conductive material is not an aerosol-forming material. The role of the carbon-based thermally conductive material in this embodiment is to facilitate heat transfer so that aerosol generation from the aerosol-forming material can be optimized.

Aerosol-forming substances may include one or more organic substances, such as tobacco. The aerosol-forming material may include one or more of herbal leaves, tobacco leaves, tobacco rib pieces, reconstituted tobacco, homogenized tobacco, extruded tobacco, and puffed tobacco. Preferably, the aerosol-forming material may be formed from homogenized tobacco. Preferably, the aerosol-forming material includes tobacco and an aerosol-forming agent. Preferably, the aerosol-forming material is configured to generate an aerosol when heated to a temperature of 120 degrees Celsius to 395 degrees Celsius. The aerosol-forming material may be a homogenized tobacco material containing an aerosol-forming agent such as glycerin or propylene glycol. The first material may further include fibers and a binder to improve the structure of the first material.

Advantageously, one or both of the fibers and the binder can increase the tensile strength of the aerosol-forming material. Increased tensile strength can allow for the production of co-laminated sheets of aerosol-forming substrates that do not tear easily. Increased tensile strength may allow production of co-laminated sheets of aerosol-forming substrates using existing production machinery.

The aerosol-forming substrate may include one or more aerosol-forming agents. Suitable aerosol formers are known in the art and include polyhydric alcohols such as propylene glycol, polyethylene glycol, triethylene glycol, 1,3-butanediol and glycerin; Esters of polyhydric alcohols such as glycerol mono-, di- or triacetate; and one or more aerosol formers selected from aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate. It may be particularly desirable for the aerosol former to be or comprise glycerin. Optionally, the aerosol-forming substrate includes one or both of glycerin and glycerol.

Optionally, the substrate comprises at least 10, 15, 20, 25, 30, 35, 40, 45, 50, or 55% by weight, on a dry weight basis, of an aerosol former. Optionally, the substrate comprises no more than 55, 50, 45, 40, 35, 30, 25, 20, or 15 weight percent of an aerosol former, on a dry weight basis. Optionally, the substrate has 7 to 60, 10 to 60, 20 to 60, 30 to 60, 40 to 60, 50 and 60, 7 and 50, 10 and 50, 20 and 50, 30 and 50, 40 by dry weight. and 50, 7 and 40, 10 and 40, 20 and 40, 7 and 30, 10 and 30, 20 and 30, 7 and 20, 10 and 20, or 7 and 10 weight percent aerosol former. It may be particularly desirable for the substrate to comprise 15 to 25% by weight, on a dry weight basis, of aerosol former.

Optionally, the substrate comprises at least 2, 4, 6, 8, 10, 12, 14, 16 or 18% fiber by weight on a dry weight basis. Optionally, the substrate comprises no more than 20, 18, 16, 14, 12, 10, 8, 6, or 4 weight percent fibers on a dry weight basis. Optionally, the substrate has 4 to 20, 6 to 20, 8 to 20, 10 to 20, 12 to 20, 14 to 20, 16 to 20, 18 to 20, 2 to 18, 4 to 18, 6 to 18, 8 to 18, 10 to 18, 12 to 18, 14 to 18, 16 to 18, 2 to 16, 4 to 16, 6 to 16, 8 to 16, 10 to 16, 12 to 16, 14 to 14 16, 2 to 14, 4 to 14, 6 to 14, 8 to 14, 10 to 14, 12 to 14, 2 to 12, 4 to 12, 6 to 12, 8 to 12, 10 to 12, 2 to 10, 4 to 10, 6 to 10, 8 to 10, 2 to 8, 4 to 8, 6 to 8, 2 to 6, 4 to 6, or 2 to 4 weight percent fibers. It may be particularly desirable for the substrate to comprise 2.1 to 9.8% by weight of fibers on a dry weight basis.

The aerosol former may be glycerin. The aerosol-forming substrate may include at least 1, 2, 5, 10, or 15 weight percent glycerin. For example, the aerosol-forming substrate may include 12 to 25 weight percent glycerin.

The aerosol-forming material may comprise fibers, preferably 2 to 20% by weight of fibers. The aerosol-forming material may comprise a binder, preferably from 2 to 10% by weight of binder.

Optionally, the substrate comprises at least 2, 4, 6, 8, 10, 12, 14, 16 or 18% fiber by weight on a dry weight basis. Optionally, the substrate comprises no more than 20, 18, 16, 14, 12, 10, 8, 6, or 4 weight percent fibers on a dry weight basis. Optionally, the substrate has 4 to 20, 6 to 20, 8 to 20, 10 to 20, 12 to 20, 14 to 20, 16 to 20, 18 to 20, 2 to 18, 4 to 18, 6 to 18, 8 to 18, 10 to 18, 12 to 18, 14 to 18, 16 to 18, 2 to 16, 4 to 16, 6 to 16, 8 to 16, 10 to 16, 12 to 16, 14 to 14 16, 2 to 14, 4 to 14, 6 to 14, 8 to 14, 10 to 14, 12 to 14, 2 to 12, 4 to 12, 6 to 12, 8 to 12, 10 to 12, 2 to 10, 4 to 10, 6 to 10, 8 to 10, 2 to 8, 4 to 8, 6 to 8, 2 to 6, 4 to 6, or 2 to 4 weight percent fibers. It may be particularly desirable for the substrate to comprise 2.1 to 9.8% by weight of fibers on a dry weight basis.

Optionally, the fibers are cellulose fibers. Advantageously, cellulosic fibers are not overly costly and can increase the tensile strength of the substrate.

Optionally, each fiber has three mutually perpendicular dimensions, the largest of the three dimensions being at least 1.5, 2, 3, 5, 10, or 20 times larger than the smallest of the three dimensions. Optionally, each fiber has three mutually perpendicular dimensions, the largest of the three dimensions being at least 1.5, 2, 3, 5, 10, or 20 times larger than the second largest of the three dimensions.

Optionally, the substrate comprises at least 4, 6, or 8 weight percent binder, on a dry weight basis. Optionally, the substrate comprises up to 8, 6, or 4 weight percent binder on a dry weight basis. Optionally, the substrate comprises 4 to 10, 6 to 10, 8 to 10, 2 to 8, 4 to 8, 6 to 8, 2 to 6, 4 to 6, 2 to 4 weight percent binder, on a dry weight basis. do. It may be particularly desirable for the substrate to comprise from 2.1 to 10% by weight of binder, on a dry weight basis.

Suitable binders are well known in the art and include natural pectins such as fruit, citrus or tobacco pectin; guar gums such as hydroxyethyl guar and hydroxypropyl guar; locust bean gum, such as hydroxyethyl and hydroxypropyl locust bean gum; alginate; Starches, such as engineered or derived starches; cellulose such as methyl, ethyl, ethylhydroxymethyl and carboxymethyl cellulose; tamarind gum; dextran; pullon; konjac flour; Includes, but is not limited to, xanthan gum. It may be particularly desirable for the binder to be or comprise guar. It may be particularly preferred if the binder comprises or consists of one or more of carboxymethyl cellulose or hydroxypropyl cellulose or gums such as guar gum.

Aerosol-forming substances may include nicotine. Optionally, the aerosol-forming substrate comprises at least 0.01, 1, 2, 3, or 4% nicotine by weight on a dry weight basis. Optionally, the aerosol-forming substrate comprises no more than 5, 4, 3, 2, or 1% nicotine by weight on a dry weight basis. Optionally, the substrate has 0.01 to 5, 1 to 5, 2 to 5, 3 to 5, 4 to 5, 0.01 to 4, 1 to 4, 2 to 4, 3 to 4, 0.01 to 3, 1, by dry weight. to 3, 2 to 3, 0.01 to 2, 1 to 2, 0.01 to 1% nicotine. It may be particularly desirable for the aerosol-forming substrate to comprise 0.5 to 3% nicotine by weight on a dry weight basis.

Optionally, nicotine is distributed substantially homogeneously throughout the aerosol-forming material.

Optionally, the aerosol-forming material includes an acid. Optionally, the aerosol-forming substrate comprises at least 0.01, 1, 2, 3, or 4 weight percent acid, on a dry weight basis. Optionally, the aerosol-forming substrate comprises up to 5, 4, 3, 2 or 1% by weight of acid on a dry weight basis. Optionally, the substrate has 0.01 to 5, 1 to 5, 2 to 5, 3 to 5, 4 to 5, 0.01 to 4, 1 to 4, 2 to 4, 3 to 4, 0.01 to 3, 1, by dry weight. to 3, 2 to 3, 0.01 to 2, 1 to 2, 0.01 to 1% by weight of acid. It may be particularly desirable for the aerosol-forming substrate to comprise 0.5 to 3% by weight of acid, on a dry weight basis.

Optionally, the acid includes or consists of one or more of fumaric acid, lactic acid, benzoic acid, and levulinic acid.

Optionally, the acid is distributed substantially homogeneously throughout the aerosol-forming material.

Optionally, the aerosol-forming material includes at least one plant. Optionally, the substrate comprises at least 0.01, 1, 2, 5, 10, or 15% by weight, on a dry weight basis, of at least one plant. Optionally, the substrate comprises no more than 20, 15, 10, 5, 2 or 1% by weight on a dry weight basis of at least one plant. Optionally, the substrate has 0.01 to 20, 1 to 20, 2 to 20, 5 to 20, 10 to 20, 15 to 20, 0.01 to 15, 1 to 15, 2 to 15, 5 to 15, 10 to 15, 0.01 to 10, 1 to 10, 2 to 10, 5 to 10, 0.01 to 5, 1 to 5, 2 to 5, 0.01 to 2, 1 to 2, 0.01 to 1% by weight of at least one plant Includes. It may be particularly desirable to comprise 5 to 15% by weight of at least one plant, on a dry weight basis.

Optionally, the at least one plant includes or consists of one or both cloves and16omprise16.

Optionally, the at least one plant is distributed substantially homogeneously throughout the aerosol-forming material.

Optionally, the aerosol-forming material includes at least one flavoring agent. Optionally, the aerosol-forming substrate includes at least 0.1, 1, 2, or 5% by weight, on a dry weight basis, of at least one flavorant. Optionally, the aerosol-forming substrate includes up to 10, 5, 2, or 1% by weight, on a dry weight basis, of at least one flavoring agent. Optionally, the substrate comprises 0.1 to 10, 1 to 10, 2 to 10, 5 to 10, 0.1 to 5, 1 to 5, 2 to 5, 0.1 to 2, 1 to 2, 0.1 to 1% by weight, by dry weight. Contains at least one flavoring agent. It may be particularly preferred for the substrate to comprise 0.5 to 4.0% by weight, on a dry weight basis, of at least one flavoring agent.

Optionally, the at least one flavoring agent is present as a coating, for example a coating on one or more other components of the aerosol-forming substrate. Alternatively or additionally, the at least one flavorant is distributed substantially homogeneously throughout the aerosol former.

Optionally, the aerosol-forming material includes at least one organic material, such as tobacco. Optionally, the at least one organic material includes one or more of herb leaves, tobacco leaves, tobacco rib pieces, reconstituted tobacco, homogenized tobacco, extruded tobacco, and puffed tobacco. Optionally, the at least one organic material is distributed substantially homogeneously throughout the aerosol-forming material.

The aerosol-forming substrate may include less than 10, 5, 3, 2, or 1% by weight of tobacco on a dry weight basis. Optionally, the aerosol-forming substrate is a tobacco-free aerosol-forming substrate.

The aerosol-forming material may comprise or be in the form of one or more sheets, for example one or more corrugated sheets. The or each sheet, for example a corrugated sheet, may have a width of at least about 10, 25, 50, or 100 millimeters. The or each sheet, for example a corrugated sheet, may have a length of at least about 3, 5 or 10 millimeters. The or each sheet, for example a corrugated sheet, may have a thickness of at least about 100, 150 or 200 microns. The sheet or individual sheets, for example corrugated sheets, may have a thickness of less than about 500, 400 or 300 microns. The sheet or individual sheets, such as corrugated sheets, may have a thickness of 100 to 500, 170 to 400, or 200 to 300 microns. The or each sheet, for example a corrugated sheet, may have a thickness of about 235 microns.

According to a second aspect, a rod is provided. The rod may be a rod for an aerosol-generating article. The rod may comprise or be formed by an aerosol-forming substrate. That is, a rod of an aerosol-forming substrate may be provided. The rod may comprise a corrugated sheet of an aerosol-forming substrate.

The rod may include a wrapper surrounding a corrugated sheet of aerosol-forming substrate. Preferably, the aerosol-forming substrate is an aerosol-forming substrate according to the first aspect. In this way, the rod can be formed by corrugating the co-laminated sheet of the first aspect.

The susceptor element can be positioned within the rod of the aerosol-forming substrate. The susceptor element may be an elongated susceptor element. The susceptor element may extend longitudinally within the aerosol-forming substrate. The rod may be substantially cylindrical, for example substantially right cylindrical in shape. The susceptor element may be located at a radially central location within the rod of the aerosol-forming substrate. The susceptor element may extend along a central longitudinal axis of the rod of the aerosol-forming substrate.

The susceptor element may extend fully to the downstream end of the rod of aerosol-forming substrate. The susceptor element may extend fully to the upstream end of the rod of aerosol-forming substrate. The susceptor element may have substantially the same length as the rod of the aerosol-forming substrate. The susceptor element may extend completely from the upstream end to the downstream end of the rod of aerosol-forming substrate.

The susceptor element may be in the form of a pin, rod, strip or blade.

The susceptor element may have a length of 5 to 15, 6 to 12, or 8 to 10 millimeters. The susceptor element can have a width of 1 to 5 millimeters. The susceptor element may have a thickness of 0.01 to 2, 0.5 to 2, or 0.5 to 1 millimeter.

Alternatively, there may be no susceptor material present within the aerosol-forming substrate or rod of the aerosol-forming substrate. Alternatively, the layer of carbon-based thermally conductive material may comprise or consist of one or more susceptor materials and may be the only susceptor material(s) present in the aerosol-forming substrate or rod of the aerosol-forming substrate. That is, there may be no susceptor elements within the aerosol-forming substrate or rods of the aerosol-forming substrate except for the layer of thermally conductive material.

Suitable susceptor materials, for example materials for susceptor elements, include carbon, carbon-based materials, graphite, expanded graphite, molybdenum, silicon carbide, stainless steel, niobium, aluminum, nickel, nickel-containing compounds, titanium, and metallic materials. Including, but not limited to, complexes. Suitable susceptor materials may include ferromagnetic materials such as ferritic iron, ferromagnetic alloys such as ferromagnetic steel or stainless steel, ferromagnetic particles, and ferrite. Suitable susceptor materials may be or include aluminum. The susceptor material preferably comprises greater than 5%, preferably greater than 20%, more preferably greater than 50% or 90% ferromagnetic or paramagnetic material. Preferred susceptor materials may include metals, metal alloys, or carbon.

Particularly preferred susceptor materials can be or include carbon, carbon-based materials, graphene, graphite, or expanded graphite. Advantageously, these materials have relatively high thermal conductivity, relatively low density and can be inductively heated. These materials may be desirable when the layer of carbon-based thermally conductive material acts as a susceptor or includes a material that acts as a susceptor.

In use, the susceptor material can convert electromagnetic energy into heat, as will be described in greater detail later with reference to aerosol-generating systems. This can heat the aerosol-forming material of the aerosol-forming substrate.

The aerosol-forming substrate may have longitudinal and transverse directions, or a radial direction perpendicular to the longitudinal direction. For example, the aerosol-forming substrate may be in the form of a plug. The plug may have a circular cylindrical shape. The plug may have a length extending in a longitudinal direction and a radius extending in a transverse direction, or a radius or direction. The longitudinal direction may refer to the direction extending from the upstream end to the downstream end of the substrate, or the direction extending from the upstream end to the downstream end of the article of which the substrate is a part. The aerosol-forming substrate is 0, 0.05, 0.1, 0.15, 0.2, 0.3, 0.4, 0.5, 0.75, 1, 1.25, 1.5, 2, 5, 10, 20, 50, 100, 200, 25 degrees Celsius in at least one direction. or may have a thermal conductivity greater than 500 W/(mK).

Advantageously, increasing the thermal conductivity of the substrate can reduce the temperature gradient of the substrate during use. When used with heating blades, it can be particularly advantageous to increase the thermal conductivity of the substrate in the transverse direction because large temperature gradients exist in the transverse direction in prior art substrates.

According to a third aspect of the present disclosure, an aerosol-generating article is provided comprising an aerosol-forming substrate. Any of the features described above in relation to the aerosol-forming substrate may apply to the aerosol-forming substrate of the aerosol-generating article.

The aerosol-generating article may be for use in an electric aerosol-generating device.

An aerosol-generating article may include multiple elements. A plurality of elements may be assembled in the form of a rod. Multiple elements may be assembled within a wrapper or casing. The aerosol-generating article may have a length of 30 mm to about 120 mm, such as 40 mm to 80 mm, such as about 45 mm. The aerosol-generating article may have a diameter of 3.5 mm to 10 mm, such as 4 mm to 8.5 mm, such as 4.5 mm to 7.5 mm.

Multiple elements may include upstream elements. The plurality of elements may include an aerosol-forming substrate. The plurality of elements may include support elements. The plurality of elements may include an aerosol cooling element. The plurality of elements may include mouthpiece elements.

The aerosol-generating article may include an intermediate hollow section. The intermediate hollow section may be positioned between the rod of the aerosol-generating substrate and the mouthpiece element. The middle hollow section may include one or both of a support element and an aerosol cooling element. The middle hollow section may consist of one or both of a support element and an aerosol cooling element.

The upstream element may be located at the upstream end of the article. The aerosol-forming substrate may be located downstream, for example directly downstream, of the upstream element. Alternatively, the aerosol-forming substrate may be located at the upstream end of the article, for example, where no upstream elements are present. The support element may be positioned downstream, for example directly downstream, of the aerosol-forming substrate. The aerosol cooling element may be positioned downstream, for example directly downstream, of the support element. The mouthpiece element may be located downstream, for example directly downstream, of the aerosol cooling element. The mouthpiece element may be located at the mouth end or downstream end of the article.

The upstream element advantageously prevents direct physical contact with the upstream end of the aerosol-forming substrate. The upstream element can also advantageously reduce the likelihood of material from the aerosol-forming substrate falling off the article. The support elements may advantageously provide support to the article and help properly position other components of the article. The aerosol cooling element can advantageously cool the aerosol to a more desirable temperature when it reaches the user. The mouthpiece element can advantageously act as a filter.

The plurality of elements of the aerosol-generating article may be assembled by means of a suitable wrapper, for example cigarette paper. Cigarette paper may be any suitable material for wrapping the components of an aerosol-generating article in the form of a rod. Materials suitable for wrappers are well known in the art. Cigarette paper can hold components of an aerosol-generating article as the article is assembled. Cigarette paper can keep the components in place within the rod.

The upstream element may be in the form of a plug, for example a porous plug. The upstream element may include one or more longitudinally extending cavities. Upstream elements may include slits or perforations. The slit or perforation may extend from the upstream end of the upstream element to the downstream end. Slits in the perforation may be suitable to allow heating pins, rods or blades to pass through them when in use. The upstream element may be made of porous material. The upstream element may be made of the same material used in one of the other components of the aerosol-generating article, such as the mouthpiece element, aerosol cooling element, or support element. The upstream element may include or be formed from one or more of filter materials, ceramics, polymeric materials, cellulose acetate, cardboard, zeolites, or aerosol-generating substrates. The upstream element may preferably comprise or be formed from cellulose acetate, for example a plug of cellulose acetate.

Optionally, the anterior plug has a length of 2 to 10, 3 to 8, or 4 to 6 mm, for example about 5 mm. Optionally, the aerosol-forming substrate within the article has a length of 5 to 20, 8 to 15, or 10 to 15 mm, for example about 12 mm.

The upstream element may have a length of 1 to 10, 3 to 8, or 4 to 6 millimeters. The upstream element may have a length of approximately 5 millimeters.

Advantageously, the upstream element may prevent the consumer from viewing the layer of thermally conductive material through the upstream end of the article.

The support element may comprise or be a hollow tube, for example a substantially cylindrical hollow tube. A hollow tube may define an internal cavity. The internal cavity may extend along the longitudinal direction. Airflow through the internal cavity may be substantially unrestricted. Accordingly, the hollow tube may not substantially contribute to the resistance to draw (RTD) of the article. The wall thickness of the hollow tube may be 2 to 4 millimeters.

The support element may be formed from any suitable material or combination of materials. For example, support elements may include cellulose acetate; cardboard; Crimped paper, for example crimped heat-resistant paper or crimped parchment paper; and polymeric materials such as low density polyethylene (LDPE). In a preferred embodiment, the support element is formed from cellulose acetate. Other suitable materials include polyhydroxyalkanoate (PHA) fibers. It may be particularly preferred that the support element comprises cellulose acetate or is formed from cellulose acetate.

The support element may have an outer diameter approximately equal to the outer diameter of the aerosol-generating article. The support element may have an outer diameter of 5 to 12, 5 to 10, or 5 to 8, 6 to 12, 6 to 10, or 6 to 8 millimeters. The support element may have an outer diameter of approximately 7.2 millimeters.

The peripheral wall of the support element may have a thickness of at least 1, 1.5 or 2 millimeters, for example if the support element comprises or is a second hollow tube.

The support element may have a length of at least 5, 6, 7 or 8 millimeters. Alternatively or additionally, the support element may have a length of less than 15, 12 or 10 millimeters.

The aerosol cooling element may comprise or be a second hollow tube, for example a substantially cylindrical second hollow tube. The second hollow tube may define a second internal cavity. The second internal cavity may extend longitudinally. Airflow through the second internal cavity may be substantially unrestricted. Accordingly, the second hollow tube may not substantially contribute to the resistance to draw (RTD) of the article. The wall thickness of the second hollow tube may be 1 to 3 millimeters.

The aerosol cooling element may be formed from any suitable material or combination of materials. For example, aerosol cooling elements include cellulose acetate; cardboard; Crimped paper, such as crimped heat-resistant paper or crimped parchment paper; and polymeric materials such as low density polyethylene (LDPE). Other suitable materials include polyhydroxyalkanoate (PHA) fibers. The aerosol cooling element may preferably comprise cellulose acetate or be formed from cellulose acetate.

The aerosol cooling element may have an outer diameter approximately equal to the outer diameter of the aerosol-generating article. The aerosol cooling element may have an outer diameter of 5 to 12, 5 to 10, or 5 to 8, 6 to 12, 6 to 10, or 6 to 8 millimeters. The aerosol cooling element may have an outer diameter of approximately 7.2 millimeters.

The aerosol cooling element may have an internal diameter of at least about 2, 2.5, or 3 millimeters, for example, if the aerosol cooling element includes or is a second hollow tube.

The peripheral wall of the aerosol cooling element may have a thickness of less than about 2.5, 1.5, 1.25, 1, 0.9, or 0.8 millimeters, for example, if the aerosol cooling element includes or is a second hollow tube.

The aerosol cooling element may have a length of at least about 5, 6, 7 or 8 millimeters. Alternatively or additionally, the aerosol cooling element may have a length of less than 15, 12 or 10 millimeters.

The mouthpiece element may include a filtration material, such as a fibrous filtration material. The mouthpiece element may include a plug of cellulose acetate or may be a plug of cellulose acetate. Mouthpiece elements may be translucent or opaque.

The mouthpiece element may have an outer diameter approximately equal to the outer diameter of the aerosol-generating article. The mouthpiece element may have an outer diameter of 5 to 12, 5 to 10, or 5 to 8, 6 to 12, 6 to 10, or 6 to 8 millimeters. The mouthpiece element may have an outer diameter of approximately 7.2 millimeters.

The mouthpiece element may have a length of at least 5, 8 or 10 millimeters. Alternatively or additionally, the mouthpiece element may have a length of less than 25, 20 or 15 millimeters. The mouthpiece element may have a length of approximately 12 millimeters.

Advantageously, longer mouthpiece elements may be more resilient to deformation, or may be better adapted to recover their initial shape after deformation, by the consumer to facilitate insertion of the aerosol-generating article into the heating device. Improved phages can be provided. Longer mouthpiece elements can provide a higher level of filtration and removal of undesirable aerosol components, allowing higher quality aerosols to be delivered. Additionally, the use of longer mouthpiece elements allows more complex mouthpieces to be provided because there is more space for integration of mouthpiece components such as capsules, threads and restrictors.

The aerosol-generating article may have an overall length of 38 to 70, 40 to 70, 42 to 70, 38 to 60, 40 to 60, or 42 to 60, 38 to 50, 40 to 50, or 42 to 50 millimeters. The aerosol-generating article may have an overall length of approximately 45 millimeters.

The aerosol-generating article may have an outer diameter of at least 5, 6, or 7 millimeters. The aerosol-generating article may have an outer diameter of less than about 12, 10, or 8 millimeters. The aerosol-generating article may have an outer diameter of approximately 7.25 millimeters.

According to the present disclosure, an aerosol-generating system is provided comprising an aerosol-generating article and an aerosol-generating device as described above.

The aerosol-generating device may be an electric aerosol-generating device. The aerosol-generating device may be combined with or separate from the aerosol-generating article. For example, an aerosol-generating device can be configured to receive at least a portion of an aerosol-generating article.

An aerosol-generating device may be configured to heat an aerosol-generating article. An aerosol-generating device may be configured to resistively heat an aerosol-generating article. The device may include a heating element. The heating element may be configured to contact, for example penetrate, the aerosol-forming substrate when in use. The heating element may be configured to be resistively heated. The heating element may include an electrical resistance track. In use, an electric current can be passed through the track to resistively heat the track. Heating elements may be in the form of pins, rods or blades.

An aerosol-generating device may be configured to inductively heat an aerosol-generating article. The device may include an inductor, such as an induction coil. The device may be configured to generate a fluctuating electromagnetic field. In use, these fluctuating electromagnetic fields may induce eddy currents in the susceptor material, such as a susceptor material of a thermally conductive material, or a susceptor material of a heating element of the device, or both. If the device comprises a heating element capable of induction heating, this heating element may be configured to contact, for example penetrate, the aerosol-forming substrate in use. Heating elements may be in the form of pins, rods or blades. Eddy currents can heat the susceptor material, which in turn can heat the aerosol-forming substrate.

In a fourth aspect of the present disclosure, a method of forming an aerosol-forming substrate is provided.

The method may include combining a layer of an aerosol-forming material with a layer of a carbon-based thermally conductive material to form a co-laminated sheet.

Aerosol-forming substrates made using this method may have the characteristics described for the first aspect.

The layer of aerosol-forming material may be a continuous sheet of aerosol-forming material. The layer of carbon-based thermally conductive material may be a continuous sheet of carbon-based thermally conductive material. In such cases, the method may include forming a continuous co-laminated sheet.

The method may further include corrugating the co-laminated sheet in a direction transverse to its longitudinal axis. The method may further include surrounding the corrugated co-laminated sheet with a wrapper to form the rod.

When the method includes forming a continuous co-laminated sheet, the corrugated sheet surrounded by a wrapper can form a continuous rod. In such cases, the method may further include cutting the continuous rod into a plurality of individual rods.

Such rods may also be used as aerosol-forming substrates in heated aerosol-generating articles. Preferably, the aerosol-generating article is a smoking article that generates an aerosol that can be inhaled directly through the user's mouth and into the user's lungs. More preferably, the aerosol-generating article is a smoking article that generates a nicotine-containing aerosol that can be inhaled directly through the user's mouth and into the user's lungs.

Combining the layers may include placing the layer of the carbon-based thermally conductive material and the layer of the aerosol-forming material in contact with each other, preferably in close contact. The method may further include crimping the layers of the carbon-based thermally conductive layer and the aerosol-forming material layer while the layers are in contact with each other. This may include feeding a layer of carbon-based thermally conductive and aerosol-forming material through a crimping roller. Crimping rollers can interlock and crimp the layers together to form a continuously crimped co-laminated sheet. The crimp co-laminated sheet may have a plurality of spaced apart ridges or corrugations that are substantially parallel to the longitudinal axis of the sheet.

As used herein, the term 'crimped' is intended to be synonymous with the term 'creped' and refers to a sheet having a plurality of substantially parallel ridges or corrugations. Preferably, the crimped sheet of homogenized tobacco material has a plurality of ridges or corrugations substantially parallel to the cylindrical axis of the rod. This advantageously facilitates the gathering of the crimped sheets of homogenized tobacco material to form rods. However, it will be appreciated that a crimped sheet of homogenized tobacco material for use in the present invention may alternatively or additionally have a plurality of substantially parallel ridges and corrugations disposed at an acute or obtuse angle to the cylindrical axis of the rod.

Combining the layers may include overlapping a sheet of carbon-based thermally conductive material on top of a sheet of aerosol-forming material.

Alternatively, combining the sheets may include superimposing a sheet of aerosol-forming material on top of a sheet of carbon-based thermally conductive material.

In either case, a continuous process can advantageously be achieved by feeding either a sheet of carbon-based thermally conductive material or an aerosol-forming material from a first bobbin to a conveyor. Other sheets of carbon-based thermally conductive material or aerosol-forming material may be fed from a first bobbin on a conveyor to a second bobbin on top of the sheet.

Optionally, the method further comprises forming a layer of aerosol-forming material. Forming the layer of aerosol-forming material may comprise steps of a papermaking process or, preferably, a casting process.

Forming the layer of aerosol-forming material may include casting a slurry containing the organic material. The organic material is preferably homogenized tobacco material.

The step of forming the sheet further includes drying the slurry to form an aerosol-forming material.

The step or steps of forming the layer of aerosol-forming material may be performed prior to the step of combining the layers and may include overlapping a sheet of carbon-based thermally conductive material on top of the sheet of aerosol-forming material.

Alternatively, the step or steps of forming the layer of aerosol-forming material may be performed simultaneously with the step of combining the layers and may include overlapping a sheet of carbon-based thermally conductive material on top of the sheet of aerosol-forming material. there is. In particular, a sheet of aerosol-forming material can be formed on top of a sheet of carbon-based thermally conductive material. Preferably, the slurry of aerosol-forming material can be cast, preferably directly, onto the carbon-based thermally conductive material. The slurry can be dried while on top of the carbon-based thermally conductive material. In this way, a co-laminated sheet can be formed simultaneously with providing a layer of aerosol-forming material. This is particularly advantageous in continuous processes to improve the speed and ease of manufacturing co-laminated sheets.

Additionally, the process of casting aerosol-forming materials often requires the slurry to be cast onto a support structure. However, casting a layer of aerosol-forming material onto a carbon-based thermally conductive material can advantageously eliminate the need for an additional support structure.

Preferably, the slurry includes an aerosol former, reinforcing fibers, and a binder. These features are described in the first aspect as features of the aerosol-forming material.

Optionally, forming the slurry includes adding fibers.

Optionally, the method, for example forming a slurry, includes first mixing the slurry. Optionally, the first mixing occurs under a first pressure of less than or equal to 500, 400, 300, 250, or 200 mbar. Optionally, the first mixing occurs for 1 to 10, 2 to 8, or 3 to 6 minutes, such as about 4 minutes.

Optionally, the method, for example forming a slurry, includes a second mixing after the first mixing. Optionally, the second mixing occurs under a second pressure that is less than the first pressure. Optionally, the second pressure is less than or equal to 500, 400, 300, 200, 150, or 100 mbar. Optionally, the second mixing occurs for 5 to 120, 5 to 80, 5 to 40, or 10 to 30 seconds, such as about 20 seconds.

Casting the slurry may include casting the slurry onto a flat support, for example steel. Alternatively, as described above, the slurry can be cast directly onto a sheet or layer of carbon-based thermally conductive material.

Optionally, after casting the slurry and before drying the slurry, the method includes setting the thickness of the slurry, for example, 100 to 1200, 200 to 1000, 300 to 900, 500 to 700 microns, e.g. For example, this may include setting it to about 600 microns.

Optionally, drying the slurry includes providing a flow of a gas, such as air, past the slurry. Optionally, the stream of gas is heated. Optionally, the stream of gas is heated to a temperature of 100 to 160 degrees Celsius, or 120 to 140 degrees Celsius. Optionally, the flow of gas is provided for 1 to 10 minutes or 2 to 5 minutes. Optionally, drying the slurry includes drying the slurry until the slurry has a moisture content of 1 to 20, 2 to 15, 2 to 10, or 3 to 7 weight percent.

Optionally, drying the slurry forms a precursor for forming sheets of aerosol-forming material.

Optionally, the method includes cutting the sheet of aerosol-forming material to form individual elements of the aerosol-forming material. In a continuous process, cutting the sheet of aerosol-forming material may be the same step as cutting the continuous rod to form individual rods.

Alternatively or additionally, the method of the fourth aspect may include forming a layer of carbon-based thermally conductive material. This may include preparing, forming or manufacturing a reconstituted carbon-based material.

Preparing the reconstituted carbon-based material may include forming a slurry comprising thermally conductive particles. The step of preparing the reconstituted carbon-based material may further include casting and drying the slurry to form the reconstituted carbon-based material.

Preferably, the slurry may include fibers. Preferably, the slurry may include a binder. The presence of one or both fibers and binders in the slurry can increase the tensile strength of the cast and dried slurry.

Optionally, the slurry may include an aerosol former.

Optionally, the slurry includes water. Optionally, the slurry includes 20 to 90, 30 to 90, 40 to 90, 40 to 85, 50 to 80, 60 to 80, or 60 to 75 weight percent water.

Optionally, forming the slurry includes forming the first mixture. The first mixture may include fibers. The first mixture may include water. The first mixture may include an aerosol former.

Forming the slurry may include forming a second mixture. The second mixture may include thermally conductive particles. The second mixture may include a binder. Forming the slurry may include adding the second mixture to the first mixture to form the combined mixture.

Optionally, the method, for example forming a slurry, includes first mixing the combined mixture. Optionally, the first mixing occurs under a first pressure of less than or equal to 500, 400, 300, 250, or 200 mbar. Optionally, the first mixing occurs for 1 to 10, 2 to 8, or 3 to 6 minutes, such as about 4 minutes.

Optionally, the method, for example forming a slurry, includes a second mixing after the first mixing. Optionally, the second mixing occurs under a second pressure that is less than the first pressure. Optionally, the second pressure is less than or equal to 500, 400, 300, 200, 150, or 100 mbar. Optionally, the second mixing occurs for 5 to 120, 5 to 80, 5 to 40, or 10 to 30 seconds, such as about 20 seconds.

Optionally, casting the slurry includes casting the slurry onto a flat support, for example steel.

Optionally, after casting the slurry and before drying the slurry, the method includes setting the thickness of the slurry, for example, setting the slurry thickness to 100 to 1200, 200 to 1000, 300 to 900, 500 to 700 microns, e.g. For example, this includes setting it to about 600 microns.

Optionally, drying the slurry includes providing a flow of a gas, such as air, over or through the slurry. Optionally, the stream of gas is heated. Optionally, the stream of gas is heated to a temperature of 100 to 160 degrees Celsius, or 120 to 140 degrees Celsius. Optionally, the flow of gas is provided for 1 to 10 or 2 to 5 minutes. Optionally, drying the slurry includes drying the slurry until the slurry has a moisture content of 1 to 20, 2 to 15, 2 to 10, or 3 to 7 weight percent.

In a fifth aspect of the present disclosure, a method of forming a rod comprising an aerosol-forming substrate is provided. The above method is,

providing a co-laminated sheet comprising a layer of an aerosol-forming material and a layer of a carbon-based thermally conductive material;

corrugating the co-laminated sheet in a transverse direction with respect to the longitudinal axis of the sheet; and

A method comprising: surrounding the corrugated co-laminated sheet with a wrapper to form a continuous rod.

The method of the fifth aspect may further comprise any step of the method of the fourth aspect.

In a sixth aspect, a method of forming an aerosol-generating article is provided comprising the method steps of the fifth aspect.

The method includes assembling an aerosol-generating article from a plurality of components, a plurality of components including an aerosol-forming substrate.

Such articles may, for example, be in the form of a rod comprising a plurality of components including an aerosol-forming substrate assembled within a wrapper or casing. The aerosol-generating article may have a length of 30 mm to 120 mm, such as 40 mm to 80 mm, such as about 45 mm. The aerosol-generating article may have a diameter of 3.5 mm to 10 mm, such as 4 mm to 8.5 mm, such as 4.5 mm to 7.5 mm.

Optionally, the aerosol-generating article includes a front plug. Optionally, the aerosol-generating article comprises a first hollow tube, such as a first hollow acetate tube. Optionally, the aerosol-generating article comprises a second hollow tube, such as a second hollow acetate tube. Optionally, the second hollow tube includes one or more ventilation holes. Optionally, the aerosol-generating article includes a mouth plug filter. Optionally, the aerosol-generating article includes a wrapper, such as a paper wrapper.

Optionally, the front plug is arranged at the most upstream end of the article. Optionally, the aerosol-forming substrate is arranged downstream of the front plug. Optionally, the first hollow tube is arranged downstream of the aerosol-forming substrate. Optionally, the second hollow tube is arranged downstream of the first hollow tube. Optionally, a mouth plug filter is arranged downstream of one or both of the first hollow tube and the second hollow tube. Optionally, the mouth plug filter is arranged at the most downstream end of the article. Optionally, the most downstream end of the article, which can be referred to as the mouth end of the article, can be configured for insertion into the user's mouth. The user may, for example, inhale directly on the mouth end of the article.

Optionally, the front plug, the aerosol-forming substrate, one or both of the first hollow tube and the second hollow tube, and the mouth plug filter are surrounded by a wrapper, such as a paper wrapper.

Optionally, the anterior plug has a length of 2 to 10, 3 to 8, or 4 to 6 mm, for example about 5 mm. Optionally, the aerosol-forming substrate within the article has a length of 5 to 20, 8 to 15, or 10 to 15 mm, for example about 12 mm. Optionally, the first hollow tube has a length of 2 to 20, 5 to 15, or 5 to 10 mm, for example about 8 mm. Optionally, the second hollow tube has a length of 2 to 20, 5 to 15, or 5 to 10 mm, for example about 8 mm. Optionally, the mouth plug filter has a length of 5 to 20, 8 to 15, or 10 to 15 mm, for example about 12 mm. The length of one or more of the front plug, aerosol-forming substrate, first hollow tube, second hollow tube, and mouth plug filter may extend in the longitudinal direction.

One or more of the front plug, aerosol-forming substrate, first hollow tube, second hollow tube, and mouth plug filter may be substantially cylindrical, for example, cylindrical in shape.

As will be understood by those skilled in the art upon reading this disclosure, features described herein with respect to one aspect may apply to any other aspect.

As used herein, the term “aerosol-forming substrate” may refer to an aerosol or a substrate capable of releasing volatile compounds capable of forming an aerosol. These volatile compounds can be released by heating the aerosol-forming substrate. The aerosol-forming substrate may include an aerosol-forming material. The aerosol-forming substrate may be adsorbed, coated, impregnated or otherwise loaded onto a carrier or support. The aerosol-forming substrate may conveniently be part of an aerosol-generating article or smoking article.

As used herein, the term “expanded graphite” may refer to a graphitic material, or a material that has a graphite-like structure. Expanded graphite can have carbon layers (eg, similar to graphite) with spacing between carbon layers that is greater than the spacing found between carbon layers in regular graphite. Expanded graphite can have carbon layers with elements or compounds inserted into the spaces between the carbon layers.

As used herein, unless otherwise specified, the term “density” may be used to refer to true density. Measurement of true density can be performed using a number of standard methods, which are often based on Archimedes' principle. The most widely used method for measuring the true density of a powder is to place the powder inside a container of known volume (pycnometer) and weigh it. The pycnometer is then filled with a fluid of known density in which the powder does not dissolve. The volume of the powder is determined by the difference between the volume shown by the pycnometer and the volume of liquid added (i.e., the volume of air displaced).

As used herein, the term “aerosol-generating article” may refer to an article that generates an aerosol or is capable of emitting an aerosol, for example, when heated.

As used herein, the term “longitudinal” may refer to the direction extending between the downstream or proximal end and the upstream or distal end of a component, such as an aerosol-forming substrate or aerosol-generating article.

As used herein, the term “transverse direction” refers to a direction perpendicular to the longitudinal direction.

As used herein, the term “aerosol-generating device” is a device used in conjunction with an aerosol-generating article to enable the generation or release of an aerosol.

As used herein, the term “sheet” refers to a generally planar, thin layered element whose width and length are substantially greater than its thickness, e.g., at least 2, 3, 5, 10, 20 or 50 times more. It can be referred to.

As used herein, the term “aerosol former” is used to describe any suitable known compound or mixture of compounds that facilitates the formation of an aerosol. The aerosol can be a dense and stable aerosol. The aerosol may be substantially resistant to thermal degradation at the operating temperature of the aerosol-forming substrate or aerosol-generating article.

As used herein, the term “rod” may refer to a generally cylindrical, for example cylindrical, element having a substantially circular, oval or elliptical cross-section.

As used herein, the term “crimped” may refer to a sheet or individual element having one or more ridges or corrugations. The ridges or corrugations may be substantially parallel. When present within a component of an aerosol-generating article, the ridges or pleats may extend longitudinally relative to the aerosol-generating article.

The invention is defined in the claims. However, a non-exhaustive list of non-limiting examples is provided below. Any one or more features of these embodiments may be combined with any one or more features of other embodiments, implementations, or aspects described herein.

Example 1. An aerosol-forming substrate for use in a heated aerosol-generating article, the aerosol-forming substrate comprising a co-laminated sheet comprising a layer of an aerosol-forming material and a layer of a carbon-based thermally conductive material.

Example 2. The method of Example 1, wherein the layer of carbon-based thermally conductive material comprises one or more of a material containing carbon, such as graphite, expanded graphite, graphene, carbon nanotubes, charcoal, and diamond. An aerosol-forming substrate, which is a material comprised thereof.

Example 3. The aerosol-forming substrate of Example 1 or Example 2, wherein the layer of carbon-based thermally conductive material may comprise or consist of at least one of graphite and expanded graphite.

Example 4. The method of any one of examples 1 to 3, wherein the width of the co-laminated sheet is greater than 10 mm, preferably greater than 20, 30, 40, 50, 60, 70, 80, 90, 100 millimeters. , aerosol-forming substrate.

Example 5. The aerosol-forming substrate of any of Examples 1-4, wherein the co-laminated sheet has a width of less than 300, 250, 200, 150 millimeters.

Example 6. The aerosol-forming substrate of any one of Examples 1 to 5, wherein the layer of aerosol-forming material of the co-laminated sheet is in close contact with the layer of thermally conductive material.

Example 7. The aerosol-forming substrate of any of Examples 1-6, wherein the layer of carbon-based thermally conductive material has a length and width similar to or the same as the length and width of the layer of aerosol-forming material.

Example 8 The method of any one of Examples 1-7, wherein the layer of carbon-based thermally-conductive material is in contact with the layer of aerosol-forming material over substantially the entire surface of the layer of thermally-conductive material. Aerosol-forming substrate.

Example 9. The aerosol-forming substrate of any of Examples 1-8, wherein the layers of co-laminated sheets form a single sheet.

Example 10. The aerosol-forming substrate of any of Examples 1-9, wherein the co-laminated sheet comprises more than one layer of aerosol-forming material.

Example 11. The aerosol-forming substrate of any of Examples 1-10, wherein the co-laminated sheet comprises more than one layer of thermally conductive material.

Example 12 The aerosol-forming substrate of Example 10, wherein each layer of aerosol-forming material is sandwiched between layers of thermally conductive material.

Example 13. The aerosol-forming substrate of Example 11, wherein the layer or each layer of thermally conductive material is sandwiched between layers of aerosol-forming material.

Example 14. The aerosol of any of Examples 1-13, wherein the co-laminated sheet comprises the layer of carbon-based thermally conductive material and one or more additional layers comprising a material other than the aerosol-forming material. Forming substrate.

Example 15. The aerosol-forming substrate according to any one of Examples 1 to 14, wherein the layer or each layer of heat-conductive material is in the form of a film or foil.

Example 16. The aerosol-forming substrate of any of Examples 1-15, wherein the or each layer of thermally conductive material is flexible.

Example 17. The aerosol-forming substrate of any of Examples 1-16, wherein the layer or each layer of aerosol-forming material is flexible.

Example 18 The aerosol-forming substrate of any of Examples 1-17, wherein the co-laminated sheet is flexible.

Example 19. The method of any one of Examples 1-18, wherein the layer or each layer of thermally conductive material has 10, 5, 3, 2, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, An aerosol-forming substrate having a thickness of less than 0.3, 0.2, 0.1, 0.09, 0.08, 0.07, 0.06, 0.05, 0.04, 0.03 or 0.02 millimeters.

Example 20. The method of any of Examples 1-19, wherein the layer or each layer of thermally conductive material has a thickness of 10 to 0.02, or 5 to 0.02, 3 to 0.02, 2 to 0.02, 1 to 0.02, or 0.9. to 0.02, 0.8 to 0.02, 0.7 to 0.02, 0.6 to 0.02, 0.5 to 0.02, 0.4 to 0.02, 0.3 to 0.02, 0.2 to 0.02, 0.1 to 0.02, 0.09 to 0.02, 0.08 to 0.02, 0.07 to 0.02, 0.06 to 0.02 , an aerosol-forming substrate having a thickness of 0.05 to 0.02, 0.04 to 0.02 millimeters.

Example 21. The aerosol-forming substrate of any of Examples 1-20, wherein the layer of carbon-based thermally conductive material comprises or consists of carbon fibers, graphite, or graphene.

Example 22 The aerosol-forming substrate of Example 21, wherein the layer of carbon-based thermally conductive material comprises or consists of expanded graphite.

Example 23 The aerosol-forming substrate of Example 21 or Example 22, wherein the layer of carbon-based thermally conductive material comprises both graphite and expanded graphite.

Example 24. The aerosol-forming substrate of any of Examples 21-23, wherein the layer of carbon-based thermally conductive material consists of flexible graphite or flexible graphite and expanded graphite foil or film.

Example 25 The aerosol-forming substrate of any of Examples 1-24, wherein the layer of carbon-based thermally conductive material has a density that is less than or equal to the density of the aerosol-forming material.

Example 26 The method of any of Examples 1-25, wherein the layer of thermally conductive material has a density that is at least 1, 2, 5, 10, 15, 20, 25, or 30% less than the density of the aerosol-forming material. An aerosol-forming substrate having a density.

Example 27 The method of any of Examples 1-26, wherein the aerosol-forming substrate has a density of less than 1050, 1000, 950, 900, 850, 800, 850, 800, 750, 700, or 650 kg/m3. An aerosol-forming substrate having,

Example 28 The aerosol-forming substrate according to any one of examples 1 to 27, wherein the aerosol-forming substrate has a density of 500 to 900 kg/m ³ , for example 600 to 800 kg/m ³ .

Example 29 The method of any of Examples 1-28, wherein the layer of carbon-based thermally conductive material has a thickness of 3, 2, 1.8, 1.5, 1.2, 1, 0.8, 0.5, 0.2, 0.1, 0.05, 0.02 cubic. An aerosol-forming substrate having a density of less than grams per centimeter (g/cm ³ ).

Example 30. The method of any of Examples 1-29, wherein the layer of carbon-based thermally conductive material has a thickness of 0.01, 0.02, 0.05, 0.1, 0.2, 0.5, 0.8, 1, 1.2, 1.5 or 1.8 cubic centimeters. An aerosol-forming substrate having a density greater than grams (g/cm ³ ).

Example 31. The method of any one of Examples 1 to 30, wherein the layer of carbon-based thermally conductive material has a thickness of 0.01 to 3, 0.01 to 2, 0.01 to 1.8, 0.01 to 1.5, 0.01 to 1.2, 0.01 to 1, 0.01 to 0.8, 0.01 to 0.5, 0.02 to 3, 0.02 to 2, 0.02 to 1.8, 0.02 to 1.5, 0.02 to 1.2, 0.02 to 1, 0.02 to 0.8, 0.02 to 0.5, 0.01 to 3, 0.05 to 2, 0 From .05 1.8, 0.05 to 1.5, 0.05 to 1.2, 0.05 to 1, 0.05 to 0.8, 0.05 to 0.5 g/cm3, 0.1 to 3, 0.1 to 2, 0.1 to 1.8, 0.1 to 1.5, 0.1 to 1.2, 0.1 to 1, 0.1 to 0.8, 0.1 to 0.5, 0.2 to 3, 0.2 to 2, 0.2 to 1.8, 0.2 to 1.5, 0.2 to 1.2, 0.2 to 1, 0.2 to 0.8, 0.2 to 0.5, 0.5 to 3, 0.5 to 2, 0.5 to 1.8 , 0.5 to 1.5, 0.5 to 1.2, 0.5 to 1, 0.5 to 0.8, 0.8 to 3, 0.8 to 2, 0.8 to 1.8, 0.8 to 1.5, 0.8 to 1.2, 0.8 to 1 Grams per cubic centimeter (g/cm3) An aerosol-forming substrate having a density of

Example 32 The method of any of Examples 1-31, wherein the layer of carbon-based thermally conductive material has a thermal conductivity greater than 1, 2, 3, 4, 5, 6, 7, 8, or 9 megapascals (Mpa). An aerosol-forming substrate having tensile strength.

Example 33 The aerosol-forming substrate of any of Examples 1-32, wherein the layer of carbon-based thermally conductive material comprises or consists of a reconstituted carbon-based material.

Example 34 The aerosol-forming substrate of Example 33, wherein the layer of carbon-based thermally conductive material comprises or consists of a reconstituted sheet of graphite.

Example 35 The aerosol-forming substrate of Example 33 or Example 34, wherein the layer of carbon-based thermally conductive material comprises or consists of a reconstituted graphite film or foil.

Example 36 The aerosol-forming substrate of any of Examples 33-35, wherein the reconstituted carbon-based material comprises thermally conductive particles.

Example 37. The aerosol formation of Example 36, wherein each of the thermally conductive particles has a thermal conductivity of at least 1 watt/meter Kelvin [W/(mK)] in at least one direction at 25 degrees Celsius. write.

Example 38 The method of Example 36 or Example 37, wherein some or all of the thermally conductive particles are carbon, for example at least 10, 30, 50, 70, 90, 95, 98, or 99% carbon by weight. An aerosol-forming substrate comprising:

Example 39. The aerosol-forming substrate of any of Examples 33-38, wherein the reconstituted carbon-based material comprises an aerosol former.

Example 40 The aerosol-forming substrate of Example 39, wherein the reconstituted carbon-based material comprises 7 to 60 weight percent of the aerosol former on a dry weight basis.

Example 41 The aerosol-forming substrate of any of Examples 33-40, wherein the reconstituted carbon-based material comprises fibers.

Example 42 The aerosol-forming substrate of Example 41, wherein the layer of reconstituted carbon-based material comprises fibers at 2 to 20 weight percent on a dry weight basis. Optionally, the fibers are cellulose fibers.

Example 43 The aerosol-forming substrate of any of Examples 33-42, wherein the reconstituted carbon-based material comprises a binder.

Example 44 The aerosol-forming substrate of Example 43, wherein the reconstituted carbon-based material comprises 2 to 10 weight percent binder, on a dry weight basis.

Example 45 The aerosol-forming substrate of any of Examples 33-44, wherein the layer of carbon-based thermally conductive material does not include tobacco.

Example 46 The aerosol-forming substrate of Example 45, wherein the layer of carbon-based thermally conductive material may not include nicotine.

Example 47 The aerosol-forming substrate of any of Examples 33-46, wherein the layer of carbon-based thermally conductive material can be formed by a casting process.

Example 48 The aerosol-forming substrate of any of Examples 1-47, wherein the co-laminated sheet comprises or has the form of a corrugated sheet.

Example 49 The method of any of Examples 1-48, wherein the layer of carbon-based thermally conductive material has a power of greater than 2, 5, 10, 20, 50, 100, 200, 500, 1000 or 1500 W/(mK). An aerosol-forming substrate having a thermal conductivity of

Example 50 The method of any of Examples 1-49, wherein the layer of carbon-based thermally-conductive material lies in or defines a plane, and wherein the thermally-conductive layer of carbon-based thermally-conductive material in the plane is 2, an aerosol-forming substrate greater than 5, 10, 20, 50, 100, 200, 500, 1000 or 1500 W/mK.

Example 51 The method of any of Examples 1-50, wherein the layer of carbon-based thermally conductive material has 10, 30, 50, 70, 80, 90, 95, 98, 99, 99.5, or 99.9 weight percent. An aerosol-forming substrate comprising excess carbon.

Example 52 The method of any of Examples 1-51, wherein the layer of carbon-based thermally conductive material constitutes no more than 90, 80, 50, 20, 10, or 5 weight percent of the aerosol-forming substrate. Aerosol-forming substrate.

Example 53 The method of any of Examples 1-52, wherein the layer of carbon-based thermally conductive material is 0.1, 0.2, 0.5, 1, 2, 3, 5, 10, 20, 30 of the aerosol-forming substrate. , constituting at least 40, or 50% by weight of the aerosol-forming substrate.

Example 54 The method of any of Examples 1 to 53, wherein the layer of carbon-based thermally conductive material is 20 to 90, 20 to 90, 30 to 90, 40 to 90, 20, and 80 of the aerosol-forming substrate. , 30 to 80, 40 to 80, 20 to 70, 30 to 70, 40 to 70, 20 to 60, 30 to 60, 40 to 60, 20 to 50, 30 to 50% by weight of the aerosol-forming substrate.

Example 55. A rod for an aerosol-generating article comprising a corrugated sheet of an aerosol-forming substrate as defined in any one of Examples 1 to 54, and a wrapper surrounding the corrugated sheet of the aerosol-forming substrate.

Example 56 The rod of Example 55, further comprising a susceptor element located within the rod of the aerosol-forming substrate.

Example 57 The rod of Example 56, wherein the susceptor element is an elongated susceptor element.

Example 58 The rod of Example 56 or Example 57, wherein the susceptor element extends longitudinally within the rod of the aerosol-forming substrate.

Example 59. The rod of any of Examples 56-58, wherein the rod has a substantially cylindrical shape.

Example 60 The rod of Example 59, wherein the susceptor element is located at a radially central position inside the rod of aerosol-forming substrate and extends along a central, longitudinal axis of the rod of aerosol-forming substrate.

Example 61. The rod of any of examples 56-60, wherein the susceptor element is in the form of a pin, rod, strip or blade.

Example 62. The rod of any of Examples 56-61, wherein the susceptor element has a length of 5 to 15, 6 to 12, or 8 to 10 millimeters.

Example 63 The rod of Example 62, wherein the layer of carbon-based thermally conductive material comprises a susceptor material.

Example 64 The rod of Example 63, wherein there are no susceptor elements within the aerosol-forming substrate or within the rod of the aerosol-forming substrate except for the layer of thermally conductive material.

Example 65. An aerosol-generating article for use with an electric aerosol-generating device, said article comprising an aerosol-forming substrate according to any one of Examples 1-64.

Example 66 The aerosol-generating article of Example 65 comprising a plurality of elements assembled within a wrapper or casing in the form of a rod.

Example 67 The aerosol-generating article of Example 66, wherein the plurality of elements comprises an upstream element, an aerosol-forming substrate, a support element, an aerosol cooling element, and a mouthpiece element.

Example 68. An aerosol-generating system comprising an aerosol-generating article as defined in any one of Examples 65-67 and an electric aerosol-generating device, wherein the aerosol-generating device is capable of being coupled and detached from the aerosol-generating article.

Example 69 The aerosol-generating system of Example 68, wherein the aerosol-generating device is configured to resistively heat the aerosol-generating article.

Example 70 The aerosol-generating system of Example 69, wherein the device comprises a heating element capable of resistive heating.

Example 71. The aerosol-generating system of Example 70, wherein the heating element comprises an electrical resistance track.

Example 72 The aerosol-generating system of Example 71, wherein the aerosol-generating device is configured to inductively heat the aerosol-generating article.

Example 73 The aerosol-generating system of Example 72, wherein the device comprises an inductor, such as an induction coil.

Example 74 The aerosol-generating system of Example 73, wherein the device is configured to generate a fluctuating electromagnetic field.

Example 75. A method of forming an aerosol-forming substrate, the method comprising combining a layer of an aerosol-forming material with a layer of a carbon-based thermally conductive material to form a co-laminated sheet.

Example 76 The method of Example 75, wherein the layer of aerosol-forming material is a continuous sheet of aerosol-forming material.

Example 77 The method of Example 75 or Example 76, wherein the layer of carbon-based thermally-conductive material is a continuous sheet of carbon-based thermally-conductive material.

Example 78 The method of any of Examples 75-77, wherein the method comprises forming a continuous co-laminated sheet.

Example 79 The method of any of Examples 75-78, further comprising corrugating the co-laminated sheet transversely to its longitudinal axis.

Example 80 The method of any of Examples 75-79, wherein the method further comprises surrounding the corrugated co-laminated sheet with a wrapper to form a rod.

Example 81 The method of Example 80, wherein the method includes forming a continuous co-laminated sheet such that the corrugated sheet surrounded by a wrapper forms a continuous rod.

Example 82 The method of Example 81, further comprising cutting the continuous rod into a plurality of individual rods.

Example 83 The method of any of Examples 75-82, wherein combining the layers comprises placing the carbon-based thermally conductive and aerosol-forming material layers in contact with each other, preferably in close contact. method.

Example 84 The method of Example 83, further comprising crimping the carbon-based thermally conductive layer and the aerosol-forming material layer while the layers are in contact with each other.

Example 85. The method of Example 84, wherein the crimping step includes feeding the carbon-based thermally conductive layer and the aerosol-forming material layer through a crimping roller to form a continuously crimped co-laminated sheet.

Example 86 The method of Example 84, wherein the crimped co-laminated sheet has a plurality of spaced ridges or corrugations substantially parallel to the longitudinal axis of the sheet.

Example 87 The method of any of Examples 75-86, wherein combining the sheets comprises overlapping the sheet of aerosol-forming material on top of the sheet of carbon-based thermally conductive material.

Example 88 The method of any of Examples 75-87, wherein combining the layers comprises overlapping the sheet of carbon-based thermally conductive material on top of the sheet of aerosol-forming material.

Example 89 The method of any of Examples 75-88, further comprising forming a layer of the aerosol-forming material.

Example 90. The method of Example 89, wherein forming the layer of aerosol-forming material comprises a step of a papermaking process or, preferably, a casting process.

Example 91 The method of Example 90, wherein forming the layer of aerosol-forming material comprises casting a slurry comprising an organic material.

Example 92 The method of Example 91, wherein forming the sheet further comprises drying the slurry to form an aerosol-forming material.

Example 93 The method of any of Examples 91-93, wherein combining the sheets comprises overlapping the sheet of aerosol-forming material on top of the sheet of carbon-based thermally conductive material, wherein the aerosol The method of claim 1 , wherein the step or steps of forming a layer of forming material are performed prior to combining the layers.

Example 94 The method of any of Examples 91-93, wherein the step or steps of forming the layer of aerosol-forming material can be performed simultaneously with combining the layers.

Example 95 The method of Example 94, wherein the sheet of aerosol-forming material is formed on top of the sheet of carbon-based thermally conductive material.

Example 96 The method of Example 95, wherein forming the sheet of aerosol-forming material comprises casting a slurry of the aerosol-forming material onto, preferably directly on, the layer of carbon-based thermally conductive material. .

Example 97 The method of Example 96, further comprising drying the slurry on top of the layer of carbon-based thermally conductive material.

Example 98 The method of any of Examples 75-97, further comprising forming a layer of the carbon-based thermally conductive material.

Example 99 The method of Example 98, wherein forming the layer of carbon-based thermally conductive material comprises preparing, forming, or fabricating a reconstituted carbon-based material.

Example 100 The method of Example 99, wherein preparing the reconstituted carbon-based material includes forming a slurry comprising thermally conductive particles.

Example 101 The method of Example 100, wherein preparing the reconstituted carbon-based material further comprises casting and drying the slurry to form the reconstituted carbon-based material.

Example 102 The method of Example 99 or Example 100, wherein the slurry comprises fibers.

Example 103 The method of any of Examples 99-102, wherein the slurry comprises a binder.

Example 104 The method of any of Examples 99-103, wherein forming the slurry further comprises forming a first mixture.

Example 105 The method of Example 104, wherein the first mixture comprises fibers.

Example 106 The method of Example 104 or Example 105, wherein forming the slurring includes forming a second mixture.

Example 107 The method of Example 106, wherein the second mixture comprises the thermally conductive particles.

Example 108. A method of forming a rod comprising an aerosol-forming substrate, comprising:

providing a co-laminated sheet comprising a layer of an aerosol-forming material and a layer of a carbon-based thermally conductive material;

corrugating the co-laminated sheet in a transverse direction with respect to its longitudinal axis; and

Wrapping the corrugated co-laminated sheet with a wrapper to form a continuous rod.

Example 109 The method of Example 108, wherein the method comprises any of the method steps defined in any of Examples 75-108.

Example 110. A method of forming an aerosol-generating article comprising the method steps of Example 108 or Example 109.

Specific embodiments will be further described for purposes of illustration only with reference to the accompanying drawings, wherein:
1 shows a schematic cross-sectional view of a first embodiment of an aerosol-generating article;
2 shows a schematic cross-section of a first equipment for forming a rod according to a specific embodiment;
3 shows a schematic cross-section of a first equipment for forming a rod according to a specific embodiment;
4 shows a schematic cross-sectional view of a first embodiment of an aerosol-generating system;
5 shows a schematic cross-sectional view of a second embodiment of the aerosol-generating system, and
Figure 6 shows a schematic cross-sectional view of a second embodiment of the aerosol-generating article.

1 shows a schematic cross-sectional view of a first embodiment of an aerosol-generating article 10. The aerosol-generating article 10 includes a rod 12 of an aerosol-forming substrate and a downstream section 14 positioned downstream of the rod 12 of the aerosol-forming substrate. The aerosol-generating article 10 also includes an upstream section 16 at a location upstream of the rod 12 of the aerosol-generating substrate. Accordingly, the aerosol-generating article 10 extends from an upstream or distal end 18 to a downstream or proximal or mouth end 20.

The aerosol-generating article has an overall length of approximately 45 millimeters.

The downstream section 14 includes a support element 22 located immediately downstream of a rod 12 of the aerosol-generating substrate, the support element 22 being longitudinally aligned with the rod 12 . In the embodiment of Figure 1, the upstream end of the support element 22 abuts the downstream end of the rod 12 of the aerosol-generating substrate. The downstream section 14 also includes an aerosol cooling element 24 located immediately downstream of the support element 22, wherein the aerosol cooling element 24 is longitudinally aligned with the rod 12 and the support element 22. do. In the embodiment of Figure 1, the upstream end of the aerosol cooling element 24 abuts the downstream end of the support element 22.

As will become apparent from the description below, the support element 22 and the aerosol cooling element 24 together define the middle hollow section 50 of the aerosol-generating article 10. Overall, the middle hollow section 50 does not contribute substantially to the overall RTD of the aerosol-generating article. The RTD of the middle hollow section 26 overall is substantially 0 millimeters H ₂ O.

The support element 22 includes a first hollow tubular segment 26 . The first hollow tubular segment 26 is provided in the form of a hollow cylindrical tube made of cellulose acetate. The first hollow tubular segment 26 defines an internal cavity 28 extending completely from the upstream end 30 of the first hollow tubular segment to the downstream end 32 of the first hollow tubular segment 20 . The internal cavity 28 is substantially empty, so that a substantially unrestricted airflow is activated along the internal cavity 28 . The first hollow tubular segment 26—and consequently the support element 22—does not contribute substantially to the overall RTD of the aerosol-generating article 10. More specifically, the RTD of the first hollow tubular segment 26 (which is essentially the RTD of the support element 22) is substantially 0 millimeters H ₂ O.

The first hollow tubular segment 26 has a length of about 8 millimeters, an outer diameter of about 7.25 millimeters, and an inner diameter (D _FTS ) of about 1.9 millimeters. Accordingly, the thickness of the peripheral wall of first hollow tubular segment 26 is approximately 2.67 millimeters.

The aerosol cooling element 24 includes a second hollow tubular segment 34 . The second hollow tubular segment 34 is provided in the form of a hollow cylindrical tube made of cellulose acetate. The second hollow tubular segment 34 defines an internal cavity 36 extending completely from the upstream end 38 of the hollow tubular segment to the downstream end 40 of the second hollow tubular segment 34 . The internal cavity 36 is substantially empty, so that a substantially unrestricted airflow is activated along the internal cavity 36 . The second hollow tubular segment 28—and, consequently, the aerosol cooling element 24—does not contribute substantially to the overall RTD of the aerosol-generating article 10. More specifically, the RTD of the second hollow tubular segment 34 (which is essentially the RTD of the aerosol cooling element 24) is substantially 0 millimeters H ₂ O.

The second hollow tubular segment 34 has a length of about 8 millimeters, an outer diameter of about 7.25 millimeters, and an inner diameter (D _STS ) of about 3.25 millimeters. Accordingly, the thickness of the peripheral wall of the second hollow tubular segment 34 is approximately 2 millimeters. Accordingly, the ratio between the inner diameter D _FTS of the first hollow tubular segment 26 and the inner diameter D _STS of the second hollow tubular segment 34 is about 0.75.

The aerosol-generating article 10 includes a ventilation zone 60 provided at a location along the second hollow tubular segment 34 . More specifically, the ventilation zone is provided approximately 2 millimeters from the upstream end of the second hollow tubular segment 34. In this embodiment, ventilation zone 60 includes a row of circumferential perforations through paper wrapper 70, and the ventilation level of aerosol-generating article 10 is about 25%.

In the embodiment of FIG. 1 , the downstream section 14 further includes a mouthpiece element 42 at a location downstream of the middle hollow section 50 . More specifically, the mouthpiece element 42 is located immediately downstream of the aerosol cooling element 24. As shown in the diagram of FIG. 1 , the upstream end of mouthpiece element 42 abuts the downstream end 40 of aerosol cooling element 24 .

The mouthpiece element 42 is provided in the form of a cylindrical plug of low density cellulose acetate.

Mouthpiece element 42 has a length of approximately 12 millimeters and an outer diameter of approximately 7.25 millimeters. The RTD of mouthpiece element 42 is approximately 12 millimeters H ₂ O. The ratio of the length of the mouthpiece element 42 to the length of the middle hollow section 50 is approximately 0.6.

The rod 12 of the aerosol-generating substrate has an outer diameter of approximately 7.25 millimeters and a length of approximately 12 millimeters.

The upstream section 16 includes an upstream element 46 located immediately upstream of a rod 12 of the aerosol-generating substrate, with the upstream element 46 longitudinally aligned with the rod 12 . In the embodiment of Figure 1, the downstream end of the upstream element 46 abuts the upstream end of the rod 12 of the aerosol-generating substrate. The upstream element 46 is provided in the form of a cylindrical plug of cellulose acetate. The upstream element 46 has a length of approximately 5 millimeters. The RTD of the upstream element 46 is approximately 30 millimeters H ₂ O.

The upstream element 46, the rod 12 of the aerosol-forming substrate, the support element 22, the aerosol cooling element 24, and the mouthpiece element 42 are surrounded by a paper wrapper 70.

The rod (12) of the aerosol-forming substrate comprises a corrugated co-laminated sheet comprising a layer of an aerosol-forming material (13) and a layer of a carbon-based thermally conductive material (15). The layer of aerosol-forming material 13 is in close contact with the layer of carbon-based thermally conductive material, one layer being laminated on top of the other. As described below, the sheet is gathered to form a plurality of substantially parallel ridges or corrugations. As such, the cross-section of the sheet shown in Figure 1 shows a plurality of aerosol-forming materials 13 sandwiched between layers of carbon-based thermally conductive material 15 resulting from a corrugated co-laminated structure of rods of aerosol-forming substrate 12. It appears to have a layer of

The aerosol-forming material 13 includes a reconstituted sheet containing tobacco material and glycerin.

The layer of carbon-based thermally conductive material 15 is a foil made of graphite, expanded graphite or both graphite and expanded graphite.

The cardboard tube 34 has a length of 16 mm and provides free space within the article 10 where volatile components generated by heating of the aerosol-forming substrate can cool and form an aerosol.

The mouthpiece element 42 is provided in the form of a cylindrical plug of low density cellulose acetate. Mouthpiece element 42 has a length of approximately 12 millimeters and an outer diameter of approximately 7.2 mm. The RTD of mouthpiece element 42 is approximately 12 millimeters H2O.

It should be clear that the configuration of the aerosol-generating article 10 in Figure 1 is intended to serve as an example only. For example, thermally enhanced aerosol-forming substrates can be used in longer, for example 80 mm long, and thinner, for example 4.5 mm diameter aerosol-generating articles.

Figure 2 shows equipment for forming a rod 12 of an aerosol-forming substrate. The equipment generally includes feeding means for providing continuous co-laminated sheets of homogenized tobacco and aluminum foil; Crimping means for crimping the continuous co-laminated sheet; Rod forming means for corrugating the continuously crimped co-laminated sheet and surrounding the corrugated material with a wrapper to form a continuous rod; and cutting means for cutting the continuous rod into a plurality of individual rods. The equipment also includes transport means for transporting the continuously co-laminated sheet of material downstream through the equipment from the feed means, via the crimping means, to the rod forming means.

As shown in Figure 2, the feeding means for providing a continuous co-laminated sheet includes a continuous co-laminated sheet comprising a layer of an aerosol-forming material and a layer of a thermally conductive material, the continuous co-laminated sheet comprising a bobbin (4). It is mounted on the top. The crimp means comprises a pair of rotary crimp rollers (6). In use, the continuous co-laminated sheet 2 is drawn from the first bobbin 4 and transported downstream to a pair of crimp rollers 6 by a transport mechanism through a series of guides and tension rollers. As the continuously co-laminated sheet 2 is fed between a pair of crimping rollers 6, the crimping rollers engage and crimp the sheet 2 into a plurality of spaced apart sheets substantially parallel to the longitudinal axis of the sheet through the equipment. Forms a continuously crimped sheet 8 with continuous ridges or corrugations.

The continuously crimped sheet 8 is transported downstream from a pair of crimped rollers 6 towards the rod forming means and fed through a converging funnel or horn 31. The converging funnel 31 brings together the continuous co-laminated sheets 8 in the transverse direction with respect to its longitudinal axis. The sheet 8 of material assumes a substantially cylindrical configuration as it passes through the converging funnel 31.

Upon exiting the converging funnel (31), the collected co-laminated sheets are wrapped in a continuous sheet of packaging material (37). A continuous sheet of packaging material is fed from bobbin 35 and wrapped around a corrugated continuous crimped sheet of homogenized tobacco material by an endless belt conveyor or garniture. As shown in Figure 1, the rod forming means is provided so that when opposing longitudinal edges of the continuous sheet of packaging material come into contact, they attach to each other to form a continuous rod. It includes adhesive application means 17 for applying adhesive to one.

The rod forming means further comprises drying means (19) downstream of the adhesive application means (17), which in use keeps the adhesive applied to the seam of the continuous rod as it is transported downstream from the rod forming means to the cutting means. Dry.

The cutting means comprises a rotary cutter 21 that cuts the continuous rod into a plurality of individual rods of unit rod length or multiple unit rod lengths.

Figure 3 shows alternative equipment for forming a rod 12 of an aerosol-forming substrate. The equipment in Figure 3 is similar to the equipment in Figure 2 and is numbered according to its features. The difference between the equipment of Figures 2 and 3 is that the equipment of Figure 3 includes separate bobbins for the continuous sheet of aerosol-forming material and the continuous sheet of thermally conductive material rather than a single bobbin comprising co-laminated sheets of aerosol-forming substrate. will be.

In the equipment of Figure 3, a continuous sheet of aerosol-forming material is mounted on a primary bobbin (23) and a continuous sheet of carbon-based thermally conductive material is mounted on a secondary bobbin (33). In use, a continuous sheet of aerosol-forming material is drawn from the primary bobbin 23 and transported downstream by a transport mechanism through a series of guides and tension rollers to a pair of crimping rollers 6. The continuous sheet carbon-based thermally conductive material is similarly drawn from the secondary bobbin 33 and transported downstream to a pair of crimp rollers 6 by a transport mechanism. Before passing through the crimping roller 6, the continuous sheet of carbon-based thermally-conductive material is brought into close contact with the aerosol-forming material so that the carbon-based thermally-conductive material overlies the aerosol-forming material. This forms a continuous co-laminated sheet comprising a layer of carbon-based thermally conductive material and a layer of aerosol-forming material that passes through crimp rollers (6). The continuous co-laminated sheet is then run through the equipment of Figure 3 in the same manner as described in connection with Figure 2.

In another embodiment, the bobbin of aerosol-forming material can be replaced with a bobbin of carbon-based thermally-conductive material such that the aerosol-forming material overlies the carbon-based thermally-conductive material before passing through the crimping roller.

In one embodiment, the aerosol-forming material described above is:

·Pre-mixing the finely shredded tobacco material, binder and guar gum with an aerosol former and glycerin to form a pre-mixture;

·Mixing the premix with water to form a slurry;

· Homogenizing the slurry using a high shear mixer;

· Casting the slurry onto a conveyor belt; and

· Formed by a casting process that includes controlling the thickness of the slurry and drying the slurry to form a large sheet of aerosol-forming material.

The process may be used to produce a continuous sheet of aerosol-forming material for the bobbin 23 of the equipment of FIG. 3.

In another embodiment, the aerosol-forming material described above is:

·Pre-mixing the finely shredded tobacco material, binder and guar gum with an aerosol former and glycerin to form a pre-mixture;

·Mixing the premix with water to form a slurry;

· Homogenizing the slurry using a high shear mixer;

· Casting the slurry onto a continuous sheet of carbon-based thermally conductive material; and

· Formed by a casting process that includes controlling the thickness of the slurry and drying the slurry to form a large sheet of aerosol-forming material.

The process can be used to manufacture continuous co-laminated sheets comprising layers of aerosol-forming materials. The process can be used to produce a continuous sheet of aerosol-forming material for the bobbin 4 of the equipment of Figure 2.

In one embodiment, the carbon-based thermally conductive material is a commercially available foil or film.

Suitable carbon-based thermally conductive materials are available from NeoGraf solutions LLC, 11709 Madison Avenue, Lakewood, Ohio, United States 44107. In particular, the eGraf SpreaderShield (registered trademark) range is a suitable carbon-based thermally conductive material. NeoGraf solutions provide low-density heat spreaders in film or foil form with in-plane conductivities of 300 to 1600 W/(mK), thicknesses as thin as 17 micrometers, and tensile strengths of more than 7 megapascals.

Another example of suitable carbon-based thermally conductive materials is Panasonic Industry's range of EYGS182307 PGS graphite sheets, available from RS Components ( https://uk.rs-online.com/web/ ).

In another embodiment, the carbon-based thermally conductive material is a reconstituted carbon-based material.

In one embodiment, the method includes forming a reconstituted carbon-based material. Slurry is formed using a laboratory disperser that can mix a viscous liquid, disperse the powder through the liquid, and remove gases from the mixture (e.g., by applying a vacuum or other suitable low pressure). In this embodiment, a commercially available laboratory disperser from PC Laborsystem was used.

To form the slurry, the first mixture is formed by adding about 7.11 grams of aerosol former, followed by about 157.5 grams of water, followed by about 1.57 grams of fiber to a laboratory disperser. These first ingredients are then mixed for 5 minutes at 600 to 700 rpm at 25 degrees Celsius to ensure a homogeneous mixture and hydrate the fibers. A second mixture is then formed by manually mixing about 32.95 grams of thermally conductive particles and about 0.92 grams of binder. This mixing of the second mixture prevents the formation of lumps in the laboratory dispersion. The second mixture is then added to the first mixture to form the combined mixture. The combined mixture is then mixed for 4 minutes at 5000 rpm under first reduced pressure conditions of 25 degrees Celsius and approximately 200 mbar. Depressurization can help ensure that the thermally conductive particles are homogeneously dispersed within the mixture and that there is little trapped air and few lumps in the combined mixture. The combined mixture is then mixed at 5000 rpm for 20 seconds under secondary reduced pressure conditions of 25 degrees Celsius and approximately 100 mbar. This second decompression helps remove any remaining air bubbles. This forms a slurry for casting.

The slurry is then cast and dried using appropriate equipment. In this implementation, commercially available Labcoater Mathis equipment is used. The equipment includes a stainless steel, flat support, and a coma blade to adjust the thickness of the slurry cast on the flat support.

The slurry is cast on a flat support, and the gap between the coma blade and the flat support is set to 0.6 millimeters. This ensures that the thickness of the slurry is less than 0.6 millimeters at any given point.

The slurry is then dried with hot air at 120 degrees Celsius to 140 degrees Celsius for 2 to 5 minutes. After this drying, a sheet of aerosol-forming substrate is formed. This sheet has a thickness of approximately 159 microns, a basis weight of approximately 125.7 grams per cubic meter, and a density of approximately 0.79 kilograms per cubic meter.

Figure 4 shows a schematic cross-sectional view of a first configuration example of the aerosol-generating system 100. System 100 includes an aerosol-generating device 102 and an aerosol-generating article 10 of FIG. 1 .

The aerosol-generating device 102 includes a battery 104, a controller 106, a heating blade 108 coupled to the battery, and a puff detection mechanism (not shown). Controller 106 is coupled to battery 104, heating blade 108, and puff detection mechanism.

Aerosol-generating device 102 further includes a housing 110 defining a substantially cylindrical cavity for receiving a portion of article 10. Heating blades 108 are centrally located within the cavity and extend longitudinally from the bottom of the cavity.

In this embodiment, the heating blades 108 include a substrate and electrical resistance tracks located on the substrate. The battery 104 is coupled to the heating blade 108 so as to pass an electric current through the electrical resistance track and heat the electrical resistance track and heating blade 108 to an operating temperature.

In use, the user inserts the article 10 into the cavity, causing the heating blade 108 to penetrate the upstream element 46 and the rod 12 of the aerosol-forming substrate of the article 10. 4 shows the article 10 inserted into the cavity of the device 102.

The user then puffs the downstream end of article 10. This causes air to flow through the air inlet (not shown) of the device 102, then through the article 10, from the upstream end 18 to the downstream end 20, and into the user's mouth.

A user puffing article 10 causes air to flow through the air inlet of the device. The puff detection mechanism detects that the air flow rate through the air inlet has increased significantly above a non-zero critical flow rate. The puff detection mechanism transmits a signal to the controller 106 accordingly. Controller 106 then controls battery 104 to pass current through the electrical resistance tracks and heat heating blades 108. This heats the rod 12 of the aerosol-forming substrate in contact with the heating blade 108.

The layer of thermally conductive material has a significantly higher thermal conductivity than the surrounding aerosol-forming material. As such, the layer of thermally conductive material can conduct thermal energy throughout the bulk of the aerosol-forming material. This may result in a greater proportion of the aerosol-forming substrate reaching a sufficiently high temperature to release volatile compounds, and thus a higher use efficiency of the aerosol-forming substrate.

Heating the aerosol-forming substrate causes the aerosol-forming substrate to release volatile compounds. These compounds are entrained by the air flowing from the upstream end 18 of the article 10 toward the downstream end 20 of the article 10. The compound cools and condenses to form an aerosol as it passes through the internal cavities 28, 36 of the support element 22 and the aerosol cooling element 24. The aerosol then passes through the mouthpiece element 42, which filters out any unwanted particles entrained in the airstream that may enter the user's mouth.

When the user stops inhaling the article 10, the airflow rate through the air inlet of the device decreases below the non-zero critical flow rate. This is detected by a puff detection mechanism. The puff detection mechanism transmits a signal to the controller 106 accordingly. Controller 106 then controls battery 104 to reduce the current through the electrical resistance track to zero.

After puffing the article 10 several times, the user may choose to replace the article 10 with a new article.

Figure 5 shows a schematic cross-sectional view of a second embodiment of the aerosol-generating system 200. System 200 includes an aerosol-generating device 202 and an aerosol-generating article 11 of FIG. 1 .

The aerosol generating device 202 includes a battery 204, a controller 206, an induction coil 208, and a puff detection mechanism (not shown). Controller 206 is coupled to battery 204, induction coil 208, and puff detection mechanism.

Aerosol-generating device 202 further includes a housing 210 defining a substantially cylindrical cavity for receiving a portion of article 11 . The induction coil 208 spirals around the cavity.

The battery 204 is coupled to the induction coil 208 to allow alternating current to pass through the induction coil 208.

In use, the user inserts the article 11 into the cavity. Figure 5 shows the article 11 inserted into the cavity of the device 202.

The user then puffs the downstream end of article 11. This causes air to flow through the air inlet (not shown) of the device 202, then through the article 11, from the upstream end 18 to the downstream end 20, and into the user's mouth.

A user puffing the article 11 causes air to flow through the air inlet of the device. The puff detection mechanism detects that the airflow velocity through the air inlet has increased above a non-zero critical flow velocity. The puff detection mechanism transmits a signal to the controller 206 accordingly. Controller 206 then controls battery 204 to pass alternating current through induction coil 208. This causes the induction coil 208 to generate a fluctuating electromagnetic field. A rod 13 of combined aerosol-forming substrate is positioned within this fluctuating electromagnetic field. The materials of thermally conductive material 15, graphite and expanded graphite, are susceptor materials. Accordingly, the fluctuating electromagnetic field causes eddy currents in the thermally conductive material 15 (which is also electrically conductive). This causes the thermally conductive material 15 to heat up, thereby also heating the adjacent aerosol-forming material.

Heating the aerosol-forming material causes the aerosol-forming material to release volatile compounds. These compounds are entrained by the air flowing from the upstream end 18 of the article 11 toward the downstream end 20 of the article 11. The compound cools and condenses to form an aerosol as it passes through the internal cavities 28, 36 of the support element and the aerosol cooling element. The aerosol then passes through the mouthpiece element 42, which filters out any unwanted particles entrained in the airstream that may enter the user's mouth.

When the user stops inhaling the article 11, the airflow rate through the air inlet of the device decreases below the non-zero critical flow rate. This is detected by a puff detection mechanism. The puff detection mechanism transmits a signal to the controller 206 accordingly. Controller 206 then controls battery 204 to reduce the current through the electrical resistance track to zero.

After puffing the article 11 several times, the user may choose to replace the article 11 with a new article.

Figure 6 shows a schematic cross-sectional view of a second embodiment of an aerosol-generating article 510. This second embodiment is identical to the first embodiment of Figure 1 except that the rod 12 of the aerosol-forming substrate is replaced by an alternative rod 512 of the aerosol-forming substrate. Identical reference numerals have been used for identical elements in the embodiments of FIGS. 1 and 6 .

The rod 512 of the aerosol-forming substrate of the second embodiment of FIG. 6 may further comprise an elongated susceptor element 580. , is identical to the rod 12 of the aerosol-forming substrate of the first embodiment of FIG. 1 .

The susceptor elements 580 are arranged substantially longitudinally within the rod 512 of the aerosol-forming substrate such that the longitudinal axis of the rod 512 of the aerosol-forming substrate is approximately parallel. As shown in the diagram of FIG. 6 , susceptor element 580 is located at a radially central location within the rod and extends effectively along the longitudinal direction of rod 12 .

The susceptor element 580 extends completely from the upstream end of the rod 512 of the aerosol-forming substrate to the downstream end. Accordingly, susceptor element 580 has substantially the same length as rod 512 of the aerosol-forming substrate.

In the embodiment of Figure 6, susceptor element 580 is provided in the form of a strip of ferromagnetic steel and has a length of approximately 12 millimeters, a thickness of approximately 60 micrometers, and a width of approximately 4 millimeters.

The aerosol-generating article 510 of FIG. 6 may be used with the aerosol-generating device 202 of FIG. 4 in the same manner as the aerosol-generating article 11 of FIG. 2. In particular, including susceptor elements 580 means that article 510 can be inductively heated regardless of whether the thermally conductive particles comprise suitable susceptor material for induction heating.

For the purposes of this description and the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, etc. are to be understood in all instances as being modified by the term “about.” Additionally, all ranges include the maximum and minimum points disclosed and include therein any intermediate ranges that may or may not be specifically recited herein. Therefore, in this context, the number A is understood as 10% of A ± A. In this context, number A can be considered to include a numerical value that is within the common standard error of measurement for the characteristic that number A modifies. In some examples used in the appended claims, the number A may deviate by the percentages recited above, so long as the amount by which A deviates does not materially affect the basic and novel feature(s) of the claimed invention. Additionally, all ranges include the maximum and minimum points disclosed and include therein any intermediate ranges that may or may not be specifically recited herein.

Claims (15)

1. An aerosol-forming substrate for use in a heated aerosol-generating article, the aerosol-forming substrate comprising a co-laminated sheet comprising a layer of an aerosol-forming material and a layer of a carbon-based thermally conductive material. 2. An aerosol-forming substrate according to claim 1, wherein the layer of carbon-based thermally conductive material is in the form of a film or foil. 3. An aerosol-forming substrate according to claim 1 or 2, wherein the layer of carbon-based thermally conductive material comprises or consists of carbon fibers, graphite or graphene. 4. An aerosol-forming substrate according to any preceding claim, wherein the layer of thermally conductive material comprises a material with a thermal conductivity of greater than 1 W/mK. 5. An aerosol-forming substrate according to any one of claims 1 to 4, wherein the co-laminated sheet comprises a corrugated sheet or is in the form of a corrugated sheet. 6. An aerosol-forming substrate according to any preceding claim, wherein the layer of thermally conductive material comprises a reconstituted carbon-based material comprising thermally conductive particles. 7. The aerosol-forming substrate of any preceding claim, wherein the layer of thermally conductive material has a tensile strength greater than 1 megapascal (MPa). A rod for an aerosol-generating article, said rod comprising an aerosol-forming substrate as defined in any one of claims 1 to 7. A heated aerosol-generating article comprising a rod according to claim 8. An aerosol-generating system comprising an aerosol-generating article according to claim 9 and an electrically operated aerosol-generating device. A method of forming an aerosol-forming substrate, comprising:
A method comprising combining a layer of an aerosol-forming material with a layer of a carbon-based thermally conductive material to form a co-laminated sheet. 12. The method of claim 11, further comprising forming a sheet of the aerosol-forming material. 13. The method of claim 12, wherein combining the sheets includes casting the sheet of aerosol-forming material on top of the sheet of carbon-based thermally conductive material. 1. A method of forming a rod comprising an aerosol-forming substrate, comprising:
Providing a co-laminated sheet comprising an aerosol-forming material and a carbon-based thermally conductive material;
forming wrinkles in the co-laminated sheet in a transverse direction with respect to its longitudinal axis;
wrapping the corrugated co-laminated sheet with a wrapper to form a continuous rod; and
A method comprising cutting said continuous rod into a plurality of individual rods. 8. A method of forming an aerosol-generating article, comprising assembling the aerosol-generating article from a plurality of components, wherein the plurality of components comprises an aerosol-forming substrate according to any one of claims 1 to 7. How to.