KR20240032913A - Improved aerosol-forming substrate - Google Patents

Abstract

10 to 90% by weight of carbon particles, on a dry weight basis; 7 to 60% by weight of aerosol former; 2 to 20% by weight fiber; and 2 to 10 weight percent of a binder. Each of the carbon particles is made of one or more of graphite, expanded graphite, graphene, carbon nanotubes, charcoal, and diamond. Aerosol-generating articles comprising an aerosol-forming substrate and a method for forming the aerosol-forming substrate are also provided.

Description

Improved aerosol-forming substrate

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

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 are typically not capable of being 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 at 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.

According to the present disclosure, an aerosol-forming substrate is provided. The aerosol-forming substrate may include 10 to 90 weight percent [wt %] of thermally conductive particles on a dry weight basis. The aerosol-forming substrate may include 7 to 60% by weight of aerosol former on a dry weight basis. The aerosol-forming substrate may include 2 to 20% fiber by weight on a dry weight basis. The aerosol-forming substrate may include from 2 to 10% by weight binder, on a dry weight basis. Each thermally conductive particle may be made of one or more of graphite, expanded graphite, graphene, carbon nanotubes, charcoal, and diamond.

Accordingly, according to the first aspect of the present disclosure, 10 to 90% by weight, on a dry weight basis, of thermally conductive particles; 7 to 60% by weight of aerosol former; 2 to 20% by weight fiber; and 2 to 10 weight percent of a binder, wherein each of the thermally conductive particles is comprised of one or more of graphite, expanded graphite, graphene, carbon nanotubes, charcoal, and diamond.

When the term “thermally conductive particles” is used to refer to particles comprising carbon, such as particles comprising or consisting of one or more of graphite, expanded graphite, graphene, carbon nanotubes, charcoal, and diamond, Thermally conductive particles may be referred to as carbon particles or carbon-containing particles.

Advantageously, the thermally conductive particles can increase the thermal conductivity of the aerosol-forming substrate. The increased thermal conductivity of the substrate 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. Additionally, the increased thermal conductivity of the substrate may cause heaters, such as heating blades configured to heat the substrate, to operate at lower temperatures and require less power. Additionally, the increased thermal conductivity of the substrate may allow the heater to heat the substrate to a temperature at which volatile compounds are released in a shorter period of time. Accordingly, increased thermal conductivity may reduce the time required to form an inhalable aerosol for the user.

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

The aerosol-forming substrate may have a thermal conductivity of at least 0.05, 0.1, 0.15, 0.2, 0.22, 0.3, 0.4, or 0.5 W/(mK) at 25°C in at least one or all directions. This thermal conductivity can be measured when the moisture content of the substrate is 0 to 20, or 5 to 15, for example about 10%. This thermal conductivity can be measured when the substrate contains 0 to 20, or 5 to 15, for example about 10% water by weight. The moisture or water content of a substrate can be measured using titrimetric methods. The moisture or water content of the substrate can be measured using the Karl Fisher method.

Optionally, some or all of the thermally conductive particles comprise at least 10, 30, 50, 70, 90, 95, 98, or 99% carbon by weight.

Optionally, some or all of the thermally conductive particles are graphite 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. Optionally, some or all of the thermally conductive particles are carbon nanotubes or carbon nanotube particles. Optionally, some or all of the thermally conductive particles are charcoal particles. Optionally, some or all of the thermally conductive particles are diamond particles, for example artificial diamond particles. Advantageously, such materials may have relatively high thermal conductivity.

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, 0.02 g/cm ³ . The 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 g/cm ³ . Expanded graphite has 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 0.02. 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 1.5 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, It may have a density of 0.8 to 2, 0.8 to 1.8, 0.8 to 1.5, 0.8 to 1.2, and 0.8 to 1 g/cm ³ .

Optionally, according to aspects wherein each of the thermally conductive particles does not necessarily consist of one or more of graphite, expanded graphite, graphene, carbon nanotubes, char, and diamond, some or all of the thermally conductive particles comprise a metal. Alternatively or additionally, some or all of the thermally conductive particles include an alloy. Alternatively or additionally, some or all of the thermally conductive particles include intermetallic. Advantageously, such materials may have relatively high thermal conductivity.

Optionally, according to an alternative aspect wherein each of the thermally conductive particles does not necessarily consist of one or more of graphite, expanded graphite, graphene, carbon nanotubes, char, and diamond, some or all of the thermally conductive particles may comprise silicon carbide, Includes one or more of silver, copper, gold, aluminum nitride, aluminum, tungsten, and boron nitride. Optionally, some or all of the thermally conductive particles are silicon carbide particles. Optionally, some or all of the thermally conductive particles are silver particles. Optionally, some or all of the thermally conductive particles are copper particles. Optionally, some or all of the thermally conductive particles are gold particles. Optionally, some or all of the thermally conductive particles are aluminum nitride particles. Optionally, some or all of the thermally conductive particles are aluminum particles. Optionally, some or all of the thermally conductive particles are tungsten particles. Optionally, some or all of the thermally conductive particles are boron nitride particles. Advantageously, such materials may have relatively high thermal conductivity.

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.

The thermally conductive particles can be characterized by 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, a number D50 particle size may be referred to as the intermediate 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, the number D10 particle size is approximately equal to the particle size of the 100th particle, the number D50 particle size is approximately equal to the particle size of the 500th particle, and the number D90 particle size is approximately equal to the particle size of the 500th particle. One would expect the particle size to be approximately equal to that of the 900th particle.

The particle size distribution may have volume D10, D50 and D90 particle sizes. The volume D10 particle size is defined such that 10% of the sum of the volumes of all particles is accounted for by 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 such that 50% of the sum of the volumes of all particles is accounted for by 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 such that 90% of the sum of the volumes of all particles is accounted for by 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 μm. am.

Optionally, the thermally conductive particles have a particle size distribution having a number D10 particle size, wherein the number D10 particle size is 1,000, 500, 200, 100, 50, 20, 10, 5, 2, 1, 0.5, or 0.2 μm. It is as follows.

A compromise must be made when determining particle size. Larger thermally conductive particles can advantageously increase the thermal conductivity of the aerosol-forming substrate 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 μm. am.

Optionally, the thermally conductive particles have a particle size distribution having a number D50 particle size, wherein the number D50 particle size is 1,000, 500, 200, 100, 50, 20, 10, 5, 2, 1, 0.5, or 0.2 μm. It is as follows.

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. It is μm.

Optionally, the thermally conductive particles have a particle size distribution having a number D90 particle size, wherein the number D90 particle size is 1,000, 500, 200, 100, 50, 20, 10, 5, 2, 1, 0.5, or 0.2 μm. It is as follows.

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 aerosol-forming substrate. 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, smaller particle size distributions can be disadvantageously 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 μm. am.

Optionally, the thermally conductive particles have a particle size distribution with a volume D10 particle size, wherein the volume D10 particle size is 1,000, 500, 200, 100, 50, 20, 10, 5, 2, 1, 0.5, or 0.2 μm. It is as follows.

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 μm. am.

Optionally, the thermally conductive particles have a particle size distribution with a volume D50 particle size, wherein the volume D50 particle size is 1,000, 500, 200, 100, 50, 20, 10, 5, 2, 1, 0.5, or 0.2 μm. It is as follows.

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

Optionally, the thermally conductive particles have a particle size distribution with a volume D90 particle size, wherein the volume D90 particle size is 1,000, 500, 200, 100, 50, 20, 10, 5, 2, 1, 0.5, or 0.2 μm. It is as follows.

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

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

Optionally, each of the thermally conductive particles has a particle size of at least 0.1, 0.2, 0.5, 1, 2, 5, 10, 20, 50, 100, 200, or 500 μm. 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 μm. It may be particularly desirable for each thermally conductive particle to have a particle size of at least 1 μm. Alternatively or additionally, it may be particularly desirable for each of the thermally conductive particles to have a particle size of 300 μm or less. Particles smaller than 1 μm can be difficult to handle during manufacturing. Additionally, particles smaller than 1 μm may be more likely to pass through filters in aerosol-generating articles containing an aerosol-forming substrate. Particles larger than 300 μm 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 μm, or a particle size of 300 μm 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 of the thermally conductive particles has three mutually perpendicular dimensions, the largest of the three dimensions being no more than 10, 8, 5, 3, or 2 times greater 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 comprise at least 10, 20, 50, 100, 200, 500, or 1000 particles. Advantageously, a larger number of particles in the aerosol-forming substrate can cause 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 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 90, by dry weight. 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.

Regarding the weight percent of thermally conductive particles in the substrate, a compromise must be made. 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

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 may contain, on a dry weight basis, 7 to 60, 10 to 60, 20 to 60, 30 to 60, 40 to 60, 50 to 60, 7 to 50, 10 to 50, 20 to 50, 30 to 50, 40 to 50, 7 to 40, 10 to 40, 20 to 40, 30 to 40, 7 to 30, 10 to 30, 20 to 30, 7 to 20, 10 to 20, or 7 to 10 weight percent Includes. It may be particularly desirable for the substrate to comprise 15 to 25% by weight, on a dry weight basis, of aerosol former.

Optionally, aerosol formers 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 aliphatic esters of mono-, di- or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate. Optionally, the aerosol-forming substrate includes one or both of glycerin and glycerin.

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 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 to 10% 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 of the fibers 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. Includes. It may be particularly desirable for the substrate to comprise from 2 to 10% by weight of binder, on a dry weight basis.

Suitable binders are well known in the art, but include natural pectins such as fruit, citrus, or tobacco pectin; guar gums such as hydroxyethyl guar and hydroxypropyl guar; Locust bean gums such as hydroxyethyl and hydroxypropyl locust bean gum; alginate; Starches, such as modified or derived starches; cellulose such as methyl, ethyl, ethylhydroxymethyl and carboxymethyl cellulose; tamarind gum; dextran; pullalon; Konjac powder; Including, but not limited to, xanthan gum, etc. It may be particularly desirable for the binder to be or comprise guar. It may be particularly preferred that 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 aerosol-forming substrate. Optionally, the aerosol former is distributed substantially homogeneously throughout the aerosol forming substrate. Optionally, the fibers are distributed substantially homogeneously throughout the aerosol-forming substrate. Optionally, the binder is distributed substantially homogeneously throughout the aerosol-forming substrate. 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.

Optionally, the substrate includes nicotine. Optionally, the substrate comprises at least 0.01, 1, 2, 3, or 4% nicotine by weight on a dry weight basis. Optionally, the 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 to 3, 2 to 3, 0.01 to 2, 1 to 2, 0.01 to 1% nicotine by weight. It may be particularly desirable for the substrate to comprise 0.5 to 4% nicotine by weight on a dry weight basis.

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

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

Optionally, the acid comprises 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 substrate.

Optionally, the substrate 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 preferred for the substrate to comprise, on a dry weight basis, 1 to 15% by weight of at least one plant.

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

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

Optionally, the substrate includes at least one flavoring agent. Optionally, the substrate comprises at least 0.1, 1, 2, or 5% by weight, on a dry weight basis, of at least one flavoring agent. Optionally, the substrate comprises up to 10, 5, 2 or 1% by weight on a dry weight basis of at least one flavoring agent. Optionally, the substrate is present in an amount of 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 weight, by dry weight. % of at least one flavoring agent. It may be particularly preferred that the substrate comprises from 0.1 to 5% by weight, on a dry weight basis, of at least one flavoring agent.

Optionally, the at least one flavorant 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-forming substrate.

Optionally, the aerosol-forming substrate 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 substrate.

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

The aerosol-forming substrate may be in the form of a rod. As such, a load of aerosol-forming substrate may be provided.

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 rod of the aerosol-forming substrate. The rod may be substantially cylindrical, for example substantially right cylindrical in shape. The susceptor element can be positioned at a radially central position 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 mm. The susceptor element may have a width of 1 to 5 mm. The susceptor element may have a thickness of 0.01 to 2, 0.5 to 2, or 0.5 to 1 mm.

Alternatively, there may be no susceptor material present within the aerosol-forming substrate or rod of the aerosol-forming substrate.

Optionally, some or each of the thermally conductive particles may be capable of inductive heating, for example to a temperature of at least 100, 150, or 200°C. Optionally, some or each of the thermally conductive particles comprises or consists of one or more susceptor materials. Advantageously, this allows the thermally conductive particles to be inductively heated. The thermally conductive particles may comprise or may be the only susceptor material(s) present within the aerosol-forming substrate or rod of the aerosol-forming substrate. That is, there may be no susceptor elements present within the aerosol-forming substrate or rods of the aerosol-forming substrate other than thermally conductive or carbon particles.

Suitable susceptor materials include carbon, carbon-based materials, graphene, graphite, expanded graphite, molybdenum, silicon carbide, stainless steel, niobium, aluminum, nickel, nickel-containing compounds, titanium, and composites of metallic materials. It is not limited. 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 may 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.

Optionally, the aerosol-forming substrate has 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 in at least one direction at 25°C. , or has a thermal conductivity greater than 500 W/(mK).

Optionally, the aerosol formation substrate is 1500, 1450, 1400, 1350, 1300, 1250, 1200, 1100, 1050, 1000, 950, 900, 850, 800, 850, 800, 750, 700, 650, or 600kg/m ³ It has the following density. Optionally, the aerosol-forming substrate has a density of 600 to 1400, 800 to 1200, or 900 to 1100 kg/m ³ . Advantageously, reducing the density of the substrate can reduce the cost of transporting the substrate.

Optionally, the aerosol-forming substrate has a moisture content of 1 to 20, or 3 to 15% by weight. This moisture content can be measured after 48 hours of equilibration at 20°C and 50% relative humidity. Optionally, the aerosol-forming substrate comprises 1 to 20, or 3 to 15 weight percent water. The moisture or water content of a substrate can be measured using titrimetric methods. The moisture or water content of the substrate can be measured using the Karl Fisher method.

Optionally, the aerosol-forming substrate comprises or is in the form of one or more of: cutouts, powder particles, granules, pellets, shreds, spaghetti, strips, threads, ribbons, or sheets. Optionally, the aerosol-forming substrate comprises or is in the form of one or more sheets or strips.

Optionally, the aerosol-forming substrate comprises or is in the form of one or more sheets, such as corrugated sheets. Optionally, the aerosol-forming substrate comprises or is in the form of a plurality of strips.

Optionally, the or each sheet or strip has a thickness of at least 5, 10, 20, 50, 100, 150, or 200 μm. Optionally, the or each sheet or strip has a thickness of no more than 2000, 1000, 500, 400, 300, or 250 μm. Optionally, the or each sheet or strip has a thickness of 100 to 350, or 150 to 300 μm.

Optionally, the or each sheet or strip has a width of at least 100, 200, 500, or 1000 μm. Optionally, the or each sheet or strip has a width of less than or equal to 2000, 1000, 500, 400, 300, 250, or 200 μm. Optionally, the or each sheet or strip has a width of 100 to 2000, or 500 to 1000, or 600 to 1000 μm.

Optionally, the or each sheet or strip has a length of at least 100, 200, 500, 1000, 2000, or 3000 μm. Optionally, the or each sheet or strip has a length of no more than 6000, 5000, 3000, 2000, 1000, 500, or 200 μm. Optionally, the or each sheet or strip has a length of 100 to 6000, or 500 to 5000, or 1000 to 4000 μm.

Optionally, the or each sheet or strip has a basis weight of at least 20, 50, or 100 g/m ² . Optionally, the or each sheet or strip has a basis weight of less than or equal to 300 g/m ² . Optionally, the or each sheet or strip has a basis weight of 20 to 300, 50 to 250, or 100 to 250 g/m ² .

Optionally, the or each sheet or strip has a density of at least 0.1, 0.2, 0.3, or 0.5 g/m ³ . Optionally, the or each sheet or strip has a density of less than or equal to 2, 1.5, 1.2, or 1 g/m ³ . Optionally, the or each sheet or strip has a density of 0.1 to 2, 0.2 to 2, 0.3 to 2, 0.3 to 1.5, or 0.3 to 1.2 g/m ³ .

When the substrate includes one or more corrugated sheets, the or each corrugated sheet can have a width of at least about 1, 2, 5, 10, 25, 50, or 100 mm.

According to the present disclosure, combined aerosol-forming substrates are also provided. The combined aerosol-forming substrate can include a first material and a second material, the first material being included in the combined aerosol-forming substrate as a first plurality of discontinuous elements, and the second material as a second plurality of discontinuous elements. Included in the combined aerosol-forming substrate. The first material may include an aerosol former. The first material may have a first thermal conductivity. The second material may have a second thermal conductivity that is greater than the first thermal conductivity.

Accordingly, according to a second aspect of the present disclosure, a combined aerosol-forming substrate is provided, the combined aerosol-forming substrate comprising:

Comprising a first material and a second material, wherein the first material is included in the combined aerosol-forming substrate as a first plurality of discontinuous elements, and the second material is a second plurality of discontinuous elements and is included in the combined aerosol-forming substrate. Included in the description,

the first material comprises an aerosol former and has a first thermal conductivity;

The second material has a second thermal conductivity that is greater than the first thermal conductivity.

Advantageously, the second material can increase the thermal conductivity of the substrate. As described above in relation to the first aspect, this may provide one or more of the following advantages: smaller temperature gradients exist in the substrate during use, the efficiency of use of the substrate is increased, and the heater of the aerosol-generating device is It can operate at lower temperatures and the time it takes to generate aerosol is reduced.

The first material may be described as having a different material composition than the second material. Optionally, the second material comprises or is an aerosol-forming substrate as described above, such as the aerosol-forming substrate of the first aspect.

Optionally, the second thermal conductivity is at least 5% greater than the first thermal conductivity, such as at least 7, 10, 12, 15, 30, 50, 100, 200, or 500% greater. Optionally, the thermal conductivity of the second material is at least 10% greater than the thermal conductivity of the first material, such as at least 12, 15, 20, 30, 50, 100, 200, or 500% greater.

Optionally, the first plurality of discontinuous elements, or the second plurality of discontinuous elements, or both the first and second plurality of discontinuous elements are elongated elements, each having a length dimension that is greater than a width dimension and a thickness dimension.

Optionally, the elongated elements are in the form of strips, shreds, threads or ribbons.

Optionally, the first plurality of discontinuous elements, or the second plurality of discontinuous elements, or both the first and second plurality of discontinuous elements are formed by a casting process, for example by a casting process followed by a cutting process.

Optionally, the first plurality of discontinuous elements, or the second plurality of discontinuous elements, or both the first and second plurality of discontinuous elements are formed by an extrusion process.

Optionally, at least a portion of the first plurality of discontinuous elements, or at least a portion of the second plurality of discontinuous elements, or at least a portion of both the first and second plurality of discontinuous elements are crimped elements. For example, each crimped element can have one or more twists or changes in direction defined in the length dimension of the crimped element.

Optionally, one or both of the first and second materials are included in the combined aerosol-forming substrate in the form of a cut herb.

Optionally, the first plurality of discontinuous elements, or the second plurality of discontinuous elements, or both the first and second plurality of discontinuous elements have an average of 5 μm to 2000 μm, such as 50 μm to 500 μm, such as 150 μm to 300 μm. It has a thickness.

Optionally, the first plurality of discontinuous elements, or the second plurality of discontinuous elements, or both the first and second plurality of discontinuous elements have an average of 100 μm to 2000 μm, such as 500 μm to 1500 μm, such as 600 μm to 1000 μm. It has width.

Optionally, the first plurality of discontinuous elements, or the second plurality of discontinuous elements, or both the first and second plurality of discontinuous elements have an average of 100 μm to 60 mm, such as 500 μm to 30 mm μm, such as 1000 μm to 10000 μm. It has length.

Advantageously, it has been found that the thickness, width and length described above facilitate the production of suitable quantities of aerosol having desirable properties when heated by a heating element of an aerosol-generating device.

Optionally, the second material includes thermally conductive particles. Optionally, the second material comprises at least 1, 2, 5, 10, 20, 30, 40, 50, 60, 70 or 80 weight percent thermally conductive particles. Optionally, the second material includes no more than 90, 80, 70, 60, 50, 40, 30, 20, 10, or 5 weight percent thermally conductive particles. Optionally, the second material has, by dry weight, 1 to 90, 2 to 90, 5 to 90, 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 weight percent thermally conductive particles.

Optionally, the second material comprises thermally conductive particles formed of a thermally conductive material selected from the list consisting of carbon, graphite, expanded graphite, graphene, and metal. Optionally, the second material is a thermally conductive material selected from the list consisting of carbon, graphite, expanded graphite, graphene, and metal, for example, each discontinuous element of the second material is a metal foil or carbon foil, e.g. For example, strips of copper foil, aluminum foil, or stainless steel foil, or graphite foil. Advantageously, these materials have relatively high thermal conductivity.

Optionally, the first material has a thermal conductivity of less than 10, 5, 2, 1, 0.5 or 0.2 W/(mK) in at least one direction at 25°C. Optionally, the second material has 0.1, 0.22, 0.3, 0.5, 1, 2, 5, 10, 20, 50, 100, 200, 500, 1000, 1500, or 1700 W/(mK) in at least one direction at 25°C. ) has excess thermal conductivity.

Optionally, the first material is configured to generate an aerosol when heated, for example to a temperature between 120°C and 395°C, and the second material is configured to generate an aerosol when heated, for example between 120°C and 350°C. It is not configured to generate aerosols when heated to a temperature of C. Optionally, both the first material and the second material are configured to generate an aerosol when heated, for example to a temperature between 120°C and 395°C.

Optionally, the first material comprises tobacco, for example the first material is formed from homogenized tobacco. Optionally, the first material comprises tobacco and an aerosol former and is configured to generate an aerosol when heated to a temperature between 120°C and 395°C. Optionally, the first material is a homogenized tobacco material and further comprises one or both of fibers and a binder.

Optionally, the second material comprises an aerosol former and thermally conductive particles constituting from 3% to 90% by weight of the second material on a dry weight basis, wherein the second material is heated to a temperature of 120°C to 395°C. It is configured to generate an aerosol when heated. Optionally, the second material comprises tobacco and an aerosol former and conductive particles constituting from 3% to 90% by weight of the second material on a dry weight basis, wherein the second material is heated at a temperature of 120°C to 395°C. It is configured to generate an aerosol when heated. Optionally, the second material is a thermally conductive homogenized tobacco material and further comprises fibers and a binder.

Optionally, the second material does not comprise tobacco, for example the second material is a thermally conductive tobacco-free material, and further comprises fibers and a binder.

Optionally, the discontinuous elements of the first material and the discontinuous elements of the second material are formed separately and mixed together in a predetermined ratio to form a combined aerosol-forming substrate.

Optionally, the ratio of the first material to the second material in the combined aerosol-forming substrate is 1:10 to 10:1, such as 1:5 to 8:1, such as 1:1 to 5:1.

Optionally, the second material is: on a dry weight basis: 40 to 80% by weight of a particulate carbon material; 10 to 40% by weight of aerosol former; 4 to 20% by weight fiber; and 2 to 10 weight percent of a binder, wherein the particulate carbon material is comprised of one or more of graphite, expanded graphite, graphene, carbon nanotubes, and char.

Optionally, the first material is: on a dry weight basis: 40 to 80% by weight of a particulate carbon material; 10 to 40% by weight of aerosol former; 4 to 20% by weight fiber; and 2 to 10% by weight of a binder, wherein the particulate carbon material is comprised of one or more of graphite, expanded graphite, graphene, carbon nanotubes, and char, and the first material has a lower heat resistance than the second material. It has conductivity.

Optionally, the particulate carbon material consists of graphite.

Optionally, the second material and the first material are homogeneously distributed within the combined aerosol-forming substrate.

According to the present disclosure, there is provided a method of forming a combined aerosol-forming substrate, such as a combined aerosol-forming substrate as described above, such as the combined aerosol-forming substrate of the second aspect. The method may include forming a first plurality of discontinuous elements from a first material. The method may include forming a second plurality of discontinuous elements from a second material. The method may include combining a first plurality of discontinuous elements with a second plurality of discontinuous elements, for example, to form a combined aerosol-forming substrate. The second material may have greater thermal conductivity than the first material.

Accordingly, according to a third aspect of the present disclosure, there is provided a method of forming a combined aerosol-forming substrate, e.g., a combined aerosol-forming substrate as described above, e.g., a combined aerosol-forming substrate of the second aspect, comprising: forming a first plurality of discontinuous elements from one material; forming a second plurality of discontinuous elements from a second material, and combining the first plurality of discontinuous elements with the second plurality of discontinuous elements to form the combined aerosol-forming substrate, 2 The material has a greater thermal conductivity than the first material.

Optionally, the method includes providing a first plurality of discontinuous elements from a first material; providing a second plurality of discontinuous elements from a second material; and combining the first plurality of discontinuous elements with a second plurality of discontinuous elements to form a combined aerosol-forming substrate, wherein the second material has a greater thermal conductivity than the first material.

Optionally, the first plurality of discontinuous elements are formed by cutting a sheet of a first material into strips and the second plurality of discontinuous elements are formed by cutting a sheet of a second material into strips.

Optionally, the first plurality of discontinuous elements and the second plurality of discontinuous elements are cut to substantially the same size.

Optionally, forming at least one of the first plurality of discontinuous elements and the second plurality of discontinuous elements may comprise, for example, the first plurality of discontinuous elements, the second plurality of discontinuous elements, or the first and second plurality of discontinuous elements. and crimping both of the discontinuous elements to be crimped elements.

Optionally, the method includes forming a first material, forming a second material, or forming both the first and second materials.

Optionally, the combined aerosol-forming substrate is a combined aerosol-forming substrate according to the second aspect.

According to a fourth aspect of the present disclosure, an aerosol-generating article is also provided.

The article may comprise an aerosol-forming substrate as described above, for example an aerosol-forming substrate according to the first aspect.

The article may comprise a combined aerosol-forming substrate as described above, for example a combined aerosol-forming substrate according to the second aspect.

The article may be manufactured by any of the methods described above.

Optionally, the article is in the form of a rod and comprises a plurality of components comprising an assembled or combined aerosol-forming substrate within a wrapper or casing.

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, a mouth plug filter is arranged at the most downstream end of the article. Optionally, the most downstream end of the article, which may be referred to as the mouth end of the article, may 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, 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 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.

According to a fourth aspect of the present disclosure, an aerosol generating system is provided.

The system may include an aerosol-generating article and an aerosol-generating device. The article may be an article as described above, for example an article according to the third aspect.

Optionally, the electrical aerosol-generating device is configured to resistively heat the aerosol-generating article when in use.

Optionally, the electric aerosol-generating device is configured to inductively heat an aerosol-generating article, such as an aerosol-forming substrate of an aerosol-generating article, when in use.

According to the present disclosure, there is provided a method of forming an aerosol-forming substrate, for example a substrate as described above, such as the substrate according to the first aspect. The method may include forming a slurry comprising one or more or all of thermally conductive particles, aerosol formers, fibers, and binders. The method may include casting and drying the slurry to form an aerosol-forming substrate or a precursor for formation into an aerosol-forming substrate.

Accordingly, according to a fifth aspect of the present disclosure, there is provided a method of forming an aerosol-forming substrate, for example a substrate as described above, such as the substrate according to the first aspect. The method is:

forming a slurry comprising the thermally conductive particles, the aerosol former, the fiber, and the binder; and

Casting and drying the slurry to form the aerosol-forming substrate or a precursor for forming into the aerosol-forming substrate.

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

Optionally, the slurry includes nicotine.

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

Therefore, the steps for forming the slurry are:

forming a first mixture comprising the aerosol former, the fiber, water, optionally the acid, and optionally the nicotine;

forming a second mixture comprising the thermally conductive particles and the binder;

and adding the second mixture to the first mixture to form the combined mixture.

The combined mixture may subsequently be formed into a slurry, for example by mixing.

Optionally, forming the first mixture includes providing an aerosol former or a solution comprising an aerosol former and nicotine.

Optionally, forming the first mixture includes adding an acid to the aerosol former or a solution comprising the aerosol former and nicotine to form the first premixture.

Optionally, forming the first mixture includes adding water to the aerosol former or a solution comprising the aerosol former and nicotine, or to the first pre-mixture to form a second pre-mixture.

Optionally, forming the first mixture includes adding fibers to the second premixture.

Optionally, forming the second mixture includes mixing the thermally conductive particles and the binder.

Optionally, the method, such as 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, e.g., forming the slurry, includes, after the first mixing, a second 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, such as a steel flat support.

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

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°C, or 120 to 140°C. 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 into an aerosol-forming substrate, wherein the precursor is a sheet of aerosol-forming material. Optionally, the method includes cutting a sheet of aerosol-forming material.

As will be understood by those skilled in the art upon reading this disclosure, features described herein with respect to one aspect may be applicable to any other aspect. For example, features described in relation to the combined aerosol-forming substrate of the second aspect, or in relation to the first second material of the combined aerosol-forming substrate of the second aspect, may be applicable to the aerosol-forming substrate of the first aspect. It can be, and vice versa .

As used herein, the term “aerosol-forming substrate” may refer to a substrate capable of releasing an aerosol or volatile compound that is 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 substrate. 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 "thermally conductive particle" means a thermal conductivity of 0.3, preferably 0.5, or more preferably 1 W/(mK) in at least one direction at 25°C, for example in all directions at 25°C. It may refer to particles having excess thermal conductivity. Particles may exhibit anisotropic or isotropic thermal conductivity.

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

As used herein, the term “particle size” may refer to a single dimension and may be used to characterize the size of a given particle. The dimension may be the diameter of a spherical particle occupying the same volume as a given particle. All particle sizes and particle size distributions herein can be obtained using standard laser diffraction techniques. Particle sizes and particle size distributions as mentioned herein can be obtained using commercially available sensors, such as the Sympatec HELOS laser diffraction sensor.

As used herein, unless otherwise specified, the term “density” may be used to refer to actual density. Therefore, unless otherwise specified, the density of a powder or plurality of particles may refer to the actual density of the powder or plurality of particles (depending on how the powder or plurality of particles is handled rather than the bulk density of the powder or plurality of particles). may vary significantly). Measurement of actual density can be performed using a number of standard methods, which are often based on Archimedes' principle. The most widely used method, when used to determine the actual density of a powder, involves the powder being placed inside a container of known volume (pycnometer) and weighed. The piconometer 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 piconometer 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 is capable of generating or 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” may refer to a direction perpendicular to the longitudinal direction.

As used herein, the term “aerosol-generating device” may refer to a device for use with an aerosol-generating article to enable the generation or release of an aerosol.

As used herein, the term “corrugated sheet” refers to an aerosol-forming substrate or aerosol that is tortuous, folded, or otherwise compressed or contracted substantially transversely to the longitudinal axis of an aerosol-forming substrate or aerosol-generating article. It may refer to a sheet of generated goods.

As used herein, the term “sheet” refers to a generally planar laminar element having a width and length that is substantially greater, for example, at least 2, 3, 5, 10, 20 or 50 times its thickness. ) can refer to.

As used herein, the term 'strip' may refer to a thin layer element that is generally planar in width and length and is substantially greater than its thickness. The width of the strip may be greater than its thickness, for example at least 2, 3, 5 or 10 times its thickness. The length of the strip may be greater than its width, for example at least 2, 3, 5 or 10 times its width.

As used herein, the term “aerosol former” may refer to any suitable known compound or mixture of compounds that, when used, 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 "aerosol cooling element" means that, when used, an aerosol formed by a substrate or by volatile compounds released from an aerosol-forming substrate passes through the aerosol cooling element and is cooled by the aerosol cooling element prior to inhalation by the consumer. may refer to a component of an aerosol-generating article located downstream of the forming substrate.

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

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

As used herein, the term “ventilation level” may refer to the volume ratio between the airflow entering an aerosol-generating article through the ventilation zone (ventilation airflow) and the sum of the aerosol airflow and ventilation airflow. The greater the ventilation level, the higher the dilution of the aerosol stream delivered to the consumer.

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 Ex1. As an aerosol-forming substrate, on a dry weight basis,

10 to 90% by weight of thermally conductive particles;

7 to 60% by weight of aerosol former;

2 to 20% by weight fiber; and

comprising 2 to 10% by weight of a binder,

An aerosol-forming substrate, wherein each of the thermally conductive particles consists of one or more of graphite, expanded graphite, graphene, carbon nanotubes, charcoal, and diamond.

Example Ex 2. The method of any of the previous examples, wherein each thermally conductive particle of said thermally conductive particle has a power of at least 0.3, 0.5, 1, 2, 5, or 10 W/(mK) in at least one direction at 25°C. An aerosol-forming substrate having thermal conductivity.

Example Ex 3. The method of any of the previous examples, 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 Ex 4. The method of any of the previous examples, wherein some or all of the thermally conductive particles are graphite particles, some or all of the thermally conductive particles are expanded graphite particles, or some or all of the thermally conductive particles are graphite. An aerosol-forming substrate, wherein some of the thermally conductive particles are expanded graphite particles.

Example Ex 5. An aerosol-forming substrate according to any of the previous examples, wherein some or all of the thermally conductive particles are diamond particles, such as artificial diamond particles.

Example Ex 6. The aerosol-forming substrate of any of the previous examples, wherein some or all of the thermally conductive particles are graphene particles.

Example Ex 7. The aerosol-forming substrate of any of the previous examples, wherein some or all of the thermally conductive particles are carbon nanotubes.

Example Ex 8. The aerosol-forming substrate of any of the previous examples, wherein some or all of the thermally conductive particles are charcoal particles.

Example Ex 9. The aerosol-forming substrate of any of the previous examples, wherein some or all of the thermally conductive particles comprise a metal.

Example Ex 10. The aerosol-forming substrate of any of the previous examples, wherein some or all of the thermally conductive particles comprise one or both of copper and aluminum.

Example Ex 11. The aerosol-forming substrate of any of the previous examples, wherein some or all of the thermally conductive particles comprise an alloy.

Example Ex 12. The aerosol-forming substrate of any of the previous examples, wherein some or all of the thermally conductive particles are intermetallic.

Example Ex 13. The method of any of the previous examples, wherein 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, An aerosol-forming substrate that is 10, 20, 50, 100, 200, or 500 μm.

Example Ex 14. The method of any of the previous examples, wherein the thermally conductive particles have a particle size distribution having a number D10 particle size, wherein the number D10 particle size is 1,000, 500, 200, 100, 50, 20, 10. , 5, 2, 1, 0.5, or 0.2 μm or less.

Example Ex 15. The method of any of the previous examples, wherein 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, An aerosol-forming substrate that is 10, 20, 50, 100, 200, or 500 μm.

Example Ex 16. The method of any of the previous examples, wherein the thermally conductive particles have a particle size distribution having a number D50 particle size, wherein the number D50 particle size is 1,000, 500, 200, 100, 50, 20, 10. , 5, 2, 1, 0.5, or 0.2 μm or less.

Example Ex 17. The method of any of the previous examples, wherein 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, An aerosol-forming substrate that is 10, 20, 50, 100, 200, or 500 μm.

Example Ex 18. The method of any of the previous examples, wherein the thermally conductive particles have a particle size distribution having a number D90 particle size, wherein the number D90 particle size is 1,000, 500, 200, 100, 50, 20, 10. , 5, 2, 1, 0.5, or 0.2 μm or less.

Example Ex 19. The method of any of the previous examples, wherein 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, An aerosol-forming substrate that is 10, 20, 50, 100, 200, or 500 μm.

Example Ex 20. The method of any of the previous examples, wherein the thermally conductive particles have a particle size distribution having a volume D10 particle size, wherein the volume D10 particle size is 1,000, 500, 200, 100, 50, 20, 10. , 5, 2, 1, 0.5, or 0.2 μm or less.

Example Ex 21. The method of any of the previous examples, wherein 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, An aerosol-forming substrate that is 10, 20, 50, 100, 200, or 500 μm.

Example Ex 22. The method of any of the previous examples, wherein the thermally conductive particles have a particle size distribution having a volume D50 particle size, wherein the volume D50 particle size is 1,000, 500, 200, 100, 50, 20, 10. , 5, 2, 1, 0.5, or 0.2 μm or less.

Example Ex 23. The method of any of the previous examples, wherein the thermally conductive particles have a particle size distribution having a volume D90 particle size, wherein the volume D90 particle size is at least 0.1, 0.2, 0.5, 1, 2, 5, An aerosol-forming substrate that is 10, 20, 50, 100, 200, or 500 μm.

Example Ex 24. The method of any of the previous examples, wherein the thermally conductive particles have a particle size distribution having a volume D90 particle size, wherein the volume D90 particle size is 1,000, 500, 200, 100, 50, 20, 10. , 5, 2, 1, 0.5, or 0.2 μm or less.

Example Ex 25. The method of any of the previous examples, wherein the thermally conductive particles have a particle size distribution having a number D10 particle size, a number D90 particle size, a volume D10 particle size and a volume D90 particle size, wherein:

The number D90 particle size is 50, 40, 30, 20, 10, or 5 times or less than the number D10 particle size,

or the volume D10 particle size is no more than 50, 40, 30, 20, 10, or 5 times the volume D10 particle size,

or the number D90 particle size is no more than 50, 40, 30, 20, 10, or 5 times the number D10 particle size and the volume D10 particle size is 50, 40, 30, 20, 10, or less than the volume D10 particle size. or 5 times or less, an aerosol-forming substrate.

Example Ex 26. The aerosol-forming substrate of any of the previous examples, wherein the thermally conductive particles have a particle size distribution, and one or both of the number D10 particle size and the volume D10 particle size is from 1 to 20 μm.

Example Ex 27. The method of any of the previous examples, wherein the thermally conductive particles have a particle size distribution, wherein one or both of the number D90 particle size and the volume D90 particle size are 50 to 300 μm or 50 to 200 μm. Aerosol-forming substrate.

Example Ex 28. The method of any of the previous examples, wherein each of the thermally conductive particles has a particle size of at least 0.1, 0.2, 0.5, 1, 2, 5, 10, 20, 50, 100, 200, or 500 μm. , aerosol-forming substrate.

Example Ex 29. The method of any of the previous examples, wherein each of the thermally conductive particles has a particle size of less than or equal to 1,000, 500, 200, 100, 50, 20, 10, 5, 2, 1, 0.5, or 0.2 μm. An aerosol-forming substrate having,

Example Ex 30. The method of any of the previous examples, wherein each of the thermally conductive particles has three mutually perpendicular dimensions, wherein the largest of the three dimensions is the smallest of the three dimensions and the third of the three dimensions. 2 An aerosol-forming substrate that is not more than 10, 8, 5, 3, or 2 times larger than one or both of its largest dimensions.

Example Ex 31. The aerosol-forming substrate of any of the previous examples, wherein each of the thermally conductive particles is substantially spherical.

Example Ex 32. The aerosol-forming substrate of any of the previous examples, wherein the thermally conductive particles comprise at least 10, 20, 50, 100, 200, 500, or 1000 particles.

Example Ex 33. The method of any of the preceding examples, wherein the substrate contains at least 20, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80 or 85% by weight on a dry weight basis of An aerosol-forming substrate comprising thermally conductive particles.

Example Ex 34. According to any of the previous examples, the substrate has, on a dry weight basis, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, or up to 15% by weight of said thermally conductive particles.

Example Ex 35. According to any of the previous examples, the substrate has a weight of 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, An aerosol-forming substrate comprising 30 to 40, 10 to 30, 20 to 30, or 10 to 20 weight percent of the thermally conductive particles.

Example Ex 36. The method of any of the previous examples, wherein the substrate contains at least 10, 15, 20, 25, 30, 35, 40, 45, 50, or 55% by weight of the aerosol former. An aerosol-forming substrate comprising:

Example Ex 37. The method of any of the previous examples, wherein the substrate comprises no more than 55, 50, 45, 40, 35, 30, 25, 20, or 15% by weight of the aerosol former. An aerosol-forming substrate.

Example Ex 38. The method of any of the previous examples, wherein the substrate contains, on a dry weight basis, 7 to 60, 10 to 60, 20 to 60, 30 to 60, 40 to 60, 50 to 50 of the aerosol former. 60, 7 to 50, 10 to 50, 20 to 50, 30 to 50, 40 to 50, 7 to 40, 10 to 40, 20 to 40, 30 to 40, 7 to 30, 10 to 30, 20 to 30, An aerosol-forming substrate comprising 7 to 20, 10 to 20, or 7 to 10% by weight, particularly preferably 15 to 25% by weight of the aerosol former.

Example Ex 39. The method of any of the previous examples, wherein the aerosol formers are: 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 aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

Example Ex 40. The aerosol-forming substrate of any of the previous examples, wherein the aerosol-forming substrate comprises one or both of glycerin and glycerol.

Example Ex 41. The aerosol-forming material of any of the previous examples, wherein the substrate comprises at least 2, 4, 6, 8, 10, 12, 14, 16 or 18% by weight of fibers on a dry weight basis. write.

Example Ex 42. The aerosol of any of the previous examples, wherein the substrate comprises no more than 20, 18, 16, 14, 12, 10, 8, 6, or 4 weight percent fibers on a dry weight basis. Formation substrate.

Example Ex 43. According to any of the previous examples, the substrate has a weight of 4 to 20, 6 to 20, 8 to 20, 10 to 20, 12 to 20, 14 to 20, 16 to 20, on a dry weight basis. , 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 16 to 16, 10 to 16, 12 to 16, 14 to 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. % fibers, particularly preferably 2 to 10% fibers by weight.

Example Ex 44. The aerosol-forming substrate of any of the previous examples, wherein the fibers are cellulosic fibers.

Example Ex 45. The method of any of the previous examples, wherein each of said fibers has three mutually perpendicular dimensions, wherein the largest of said three dimensions is at least 1.5, 2, 3, 5 smaller than the smallest of said three dimensions. , 10, or 20 times larger, aerosol-forming substrate.

Example Ex 46. The method of any of the previous examples, wherein each of the fibers has three mutually perpendicular dimensions, the largest of the three dimensions being at least 1.5, 2, 3 greater than the second largest of the three dimensions. , 5, 10, or 20 times larger, aerosol-forming substrate.

Example Ex 47. The aerosol-forming substrate of any of the previous examples, wherein the substrate comprises at least 4, 6, or 8 weight percent of the binder on a dry weight basis.

Example Ex 48. The aerosol-forming substrate of any of the previous examples, wherein the substrate comprises up to 8, 6, or 4 weight percent of the binder on a dry weight basis.

Example Ex 49. The method of any of the previous examples, wherein the substrate has, on a dry weight basis, 4-10, 6-10, 8-10, 2-8, 4-8, 6-8, 2-6, An aerosol-forming substrate comprising 4 to 6, 2 to 4% by weight of said binder, particularly preferably 2 to 10% by weight of said binder.

Example Ex 50. The aerosol-forming substrate of any of the previous examples, wherein the binder comprises or consists of one or both carboxymethyl cellulose or hydroxypropyl cellulose.

Example Ex 51. The aerosol-forming substrate of any of the previous examples, wherein the binder comprises or consists of one or more gums, such as guar gum.

Example Ex 52. The aerosol-forming substrate of any of the previous examples, wherein the thermally conductive particles are distributed substantially homogeneously throughout the aerosol-forming substrate.

Example Ex 53. The aerosol-forming substrate of any of the previous examples, wherein the aerosol-forming agent is distributed substantially homogeneously throughout the aerosol-forming substrate.

Example Ex 54. The aerosol-forming substrate of any of the previous examples, wherein the fibers are distributed substantially homogeneously throughout the aerosol-forming substrate.

Example Ex 55. The aerosol-forming substrate of any of the previous examples, wherein the binder is distributed substantially homogeneously throughout the aerosol-forming substrate.

Example Ex 56. The aerosol-forming substrate of any of the previous examples, wherein the substrate comprises nicotine.

Example Ex 57. The aerosol-forming substrate of Example Ex 56, wherein the substrate comprises at least 0.01, 1, 2, 3, or 4 weight percent nicotine on a dry weight basis.

Example Ex 58. The aerosol-forming substrate of any of Examples Ex 56 to Ex 57, wherein the substrate comprises no more than 5, 4, 3, 2, or 1% nicotine by weight on a dry weight basis.

Example Ex 59. The method of any of the previous examples, wherein the substrate has, on a dry weight basis, 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 to 3, 2 to 3, 0.01 to 2, 1 to 2, 0.01 to 1% by weight of nicotine, particularly preferably 0.5 to 4% by weight of nicotine. An aerosol-forming substrate.

Example Ex 60. The aerosol-forming substrate of any of Examples Ex 56 to Ex 58, wherein the nicotine is distributed substantially homogeneously throughout the aerosol-forming substrate.

Example Ex 61. The aerosol-forming substrate of any of the previous examples, wherein the substrate comprises an acid.

Example Ex 62. The aerosol-forming substrate of Example Ex 61, wherein the substrate comprises at least 0.01, 1, or 2% by weight, on a dry weight basis, of the acid.

Example Ex 63. The aerosol-forming substrate of any of Examples Ex 61 to Ex 62, wherein the substrate comprises up to 3, 2 or 1% by weight of the acid on a dry weight basis.

Example Ex 64. The method of any one of Examples Ex 61 to Ex 63, wherein the substrate has 0.01 to 3, 1 to 3, 2 to 3, 0.01 to 2, 1 to 2, 0.01 to 1 weight, on a dry weight basis. % of said acid, particularly preferably 0.5 to 5% by weight of said acid.

Example Ex 65. The aerosol-forming substrate of any of Examples Ex 61 to Ex 64, wherein the acid comprises or consists of one or more of fumaric acid, lactic acid, benzoic acid, and levulinic acid.

Example Ex 66. The aerosol-forming substrate of any of Examples Ex 61 to Ex 65, wherein the acid is distributed substantially homogeneously throughout the aerosol-forming substrate.

Example Ex 67. The aerosol-forming substrate of any of the previous examples, wherein the substrate comprises at least one plant.

Example Ex 68. The aerosol-forming substrate of Example Ex 67, wherein the substrate comprises at least 0.01, 1, 2, 5, 10, or 15% by weight, on a dry weight basis, of the at least one plant.

Example Ex 69. The method of any one of Examples Ex 67 to Ex 68, wherein the substrate comprises no more than 20, 15, 10, 5, 2 or 1% by weight, on a dry weight basis, of the at least one plant. Aerosol-forming substrate.

Example Ex 70. The method of any one of Examples Ex 67 to Ex 69, wherein the substrate has 0.01 to 20, 1 to 20, 2 to 20, 5 to 20, 10 to 20, 15 to 20, on a dry weight basis. , 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 An aerosol-forming substrate comprising from 2, 1 to 2, 0.01 to 1% by weight of said at least one plant, particularly preferably from 1 to 15% by weight of said at least one plant.

Example Ex 71. The aerosol-forming substrate according to any one of Examples Ex 67 to Ex 70, wherein the at least one plant comprises or consists of one or both of cloves and rosmarinus.

Example Ex 72. The aerosol-forming substrate according to any one of Examples Ex 67 to Ex 71, wherein the at least one plant is distributed substantially homogeneously throughout the aerosol-forming substrate.

Example Ex 73. The aerosol-forming substrate of any of the previous examples, wherein the substrate comprises at least one flavorant.

Example Ex 74. The aerosol-forming substrate of Example Ex 73, wherein the substrate comprises at least 0.1, 1, 2, or 5% by weight, on a dry weight basis, of the at least one flavorant.

Example Ex 75. The aerosol-forming substrate of any of Examples Ex 73 to Ex 74, wherein the substrate comprises up to 10, 5, 2 or 1% by weight, on a dry weight basis, of the at least one flavorant. .

Example Ex 76. The method of any one of Examples Ex 73 to Ex 75, wherein the substrate has, on a dry weight basis, 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 of said at least one flavoring agent, particularly preferably 0.1 to 5% by weight of said at least one flavoring agent.

Example Ex 77. The aerosol-forming substrate according to any one of examples Ex 73 to Ex 76, wherein 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.

Example Ex 78. The aerosol-forming substrate of any one of Examples Ex 73 to Ex 77, wherein the at least one flavoring agent is distributed substantially homogeneously throughout the aerosol-forming substrate.

Example Ex 79. The aerosol-forming substrate of any of the previous examples, wherein the aerosol-forming substrate comprises one or more organic materials, such as tobacco.

Example Ex 80. The aerosol-forming substrate of any of the previous examples, wherein the organic material comprises one or more of herb leaves, tobacco leaves, tobacco rib pieces, reconstituted tobacco, homogenized tobacco, extruded tobacco, and puffed tobacco.

Example Ex 81. The aerosol-forming substrate of any of the previous examples, wherein the organic material is distributed substantially homogeneously throughout the aerosol-forming substrate.

Example Ex 82. The aerosol-forming substrate of any of the previous examples, wherein the aerosol-forming substrate is a tobacco-free aerosol-forming substrate.

Example Ex 83. The aerosol-forming substrate of any of the previous examples, wherein some or each of the thermally conductive particles comprises a susceptor material.

Example Ex 84. The method of any of the previous examples, wherein the aerosol-forming substrate has at least 0.15, 0.2, 0.22, 0.3, 0.4, 0.5, 0.75, 1, 1.25, or An aerosol-forming substrate having a thermal conductivity of 1.5 W/(mK).

Example Ex 85. The method of any of the previous examples, wherein the aerosol-forming substrate has a density of less than 1500, 1050, 1000, 950, 900, 850, 800, 850, 800, 750, 700, or 650 kg/m ³ An aerosol-forming substrate having,

Example Ex 86. Aerosol-forming substrate according to any of the previous examples, wherein the aerosol-forming substrate has a density of 500 to 900 or 600 to 800 kg/m ³ .

Example Ex 87. The aerosol-forming substrate of any of the previous examples, wherein the aerosol-forming substrate has a moisture content of 1 to 20, or 3 to 15% by weight.

Example Ex 88. The aerosol-forming substrate of any of the previous examples, wherein the aerosol-forming substrate comprises 1 to 20, or 3 to 15 weight percent water.

Example Ex 89. The aerosol-forming substrate of any of the previous examples, wherein the aerosol-forming substrate comprises or is in the form of one or more of: cut fillers, powder particles, granules, pellets, shreds, spaghetti, strips or sheets. write.

Example Ex 90. An aerosol-forming substrate according to any of the preceding examples, wherein the aerosol-forming substrate comprises or is in the form of one or more sheets or strips.

Example Ex 91. An aerosol-forming substrate according to any of the preceding examples, wherein the aerosol-forming substrate comprises or is in the form of one or more corrugated sheets.

Example Ex 92. The aerosol-forming substrate of Example Ex 91, wherein the or each corrugated sheet has a width of at least about 5, 10, 25, 50, or 100 mm.

Example Ex 93. An aerosol-forming substrate according to any of the preceding examples, wherein the aerosol-forming substrate comprises a plurality of strips or is in the form of a plurality of strips.

Example Ex 94. The aerosol-forming substrate of any of Example Ex 93, wherein each of the plurality of strips has a length of at least about 3, 5, or 10 mm.

Example Ex 95. The aerosol-forming substrate of any of Examples Ex 93 to Ex 94, wherein each of the plurality of strips has a width of less than about 3, 2, or 1 mm.

Example Ex 96. The aerosol-forming substrate of any of Examples Ex 90 to Ex 95, wherein the or each sheet or strip has a thickness of at least 100, 150, or 200 μm.

Example Ex 97. The aerosol-forming substrate according to any one of Examples Ex 90 to Ex 96, wherein the or each sheet or strip has a thickness of 300, or 250 μm or less.

Example Ex 98. The aerosol-forming substrate of any of Examples Ex 90 to Ex 97, wherein the or each sheet or strip has a thickness of 100 to 300, or 150 to 250, or 200 to 250 μm.

Example Ex 99. The aerosol-forming substrate of any of Examples Ex 90 to Ex 98, wherein the or each sheet or strip has a basis weight of at least 20, 50, or 100 g/m ² .

Example Ex 100. The aerosol-forming substrate according to any one of Examples Ex 90 to Ex 99, wherein the or each sheet or strip has a basis weight of less than or equal to 300 g/m ² .

Example Ex 101. The aerosol-forming substrate of any of Examples Ex 90 to Ex 100, wherein the or each sheet or strip has a basis weight of 20 to 300, 50 to 250, or 100 to 250 g/m ² .

Example Ex 102. The aerosol-forming substrate of any of Examples Ex 90 to Ex 101, wherein the or each sheet or strip has a density of at least 0.1, 0.2, 0.3, or 0.5 g/m ³ .

Example Ex 103. The aerosol-forming substrate of any of Examples Ex 90 to Ex 102, wherein the or each sheet or strip has a density of less than or equal to 2, 1.5, 1.2, or 1 g/m ³ .

Example Ex 104. The method of any of Examples Ex 90 to Ex 103, wherein the or each sheet or strip has 0.1 to 2, 0.2 to 2, 0.3 to 2, 0.3 to 1.5, or 0.3 to 1.2 g/m ³ An aerosol-forming substrate having a density of

Example Ex 105. Combined aerosol-forming substrate,

Comprising a first material and a second material, wherein the first material is included in the combined aerosol-forming substrate as a first plurality of discontinuous elements, and the second material is a second plurality of discontinuous elements and is included in the combined aerosol-forming substrate. Included in the description,

the first material comprises an aerosol former and has a first thermal conductivity;

wherein the second material has a second thermal conductivity that is greater than the first thermal conductivity.

Example Ex 106. Example Ex 105, wherein the second material comprises an aerosol-forming substrate according to any of Examples Ex 1 to Ex 104, or an aerosol-forming substrate according to any of Examples Ex 1 to Ex 104. A substrate, a combined aerosol-forming substrate.

Example Ex 107. Example Ex 105 or Ex 106, wherein the second thermal conductivity is at least 5% greater than the first thermal conductivity, for example at least 7% greater, at least 10% greater, or A combined aerosol-forming substrate that is at least 12% larger, or at least 15% larger.

Example Ex 108. The method of any one of Examples Ex 105 to Ex 107, wherein the thermal conductivity of the second material is at least 10% greater than the thermal conductivity of the first material, for example at least 12% greater, or A combined aerosol-forming substrate that is at least 15% larger, or at least 20% larger.

Example Ex 109. The method of any of Examples Ex 105 through Ex 108, wherein the first plurality of discontinuous elements, or the second plurality of discontinuous elements, or both the first and second plurality of discontinuous elements are three A combined aerosol-forming substrate comprising elongated elements, each having a length dimension that is greater than the width dimension and the thickness dimension.

Example Ex 110. Combined aerosol-forming substrate according to Example Ex 109, wherein the elongated elements are in the form of strips, shreds, threads or ribbons.

Example Ex 111. The method of any of Examples Ex 105 to Ex 110, wherein the first plurality of discontinuous elements, or the second plurality of discontinuous elements, or both the first and second plurality of discontinuous elements are cast. A combined aerosol-forming substrate formed by a process, for example by a casting process followed by a cutting process.

Example Ex 112. The method of any of Examples Ex 105 through Ex 111, wherein the first plurality of discontinuous elements, or the second plurality of discontinuous elements, or both the first and second plurality of discontinuous elements are extruded. A combined aerosol-forming substrate formed by a process.

Example Ex 113. The method of any of Examples Ex 105 to Ex 112, wherein at least a portion of the first plurality of discontinuous elements, or at least a portion of the second plurality of discontinuous elements, or the first and second plurality of discontinuous elements A combined aerosol-forming substrate, wherein at least a portion of both the discontinuous elements are crimped elements, for example each crimped element has one or more twists or directional changes defined in the length dimension of the crimped element.

Example Ex 114. The combined method of any one of Examples Ex 105 to Ex 113, wherein one or both of said first material and said second material are included in said combined aerosol-forming substrate in the form of a cut filler. Aerosol-forming substrate.

Example Ex 115. The method of any of Examples Ex 105 to Ex 114, wherein the first plurality of discontinuous elements, or the second plurality of discontinuous elements, or both the first and second plurality of discontinuous elements are 5 μm. A combined aerosol-forming substrate having an average thickness of between 2000 μm, such as between 50 μm and 500 μm, such as between 150 μm and 300 μm.

Example Ex 116. The method of any of Examples Ex 105 to Ex 115, wherein the first plurality of discontinuous elements, or the second plurality of discontinuous elements, or both the first and second plurality of discontinuous elements are 100 μm. A combined aerosol-forming substrate having an average width of between 2000 μm, such as 500 μm and 1500 μm, such as between 600 μm and 1000 μm.

Example Ex 117. The method of any of Examples Ex 105 to Ex 116, wherein the first plurality of discontinuous elements, or the second plurality of discontinuous elements, or both the first and second plurality of discontinuous elements are 100 μm. A combined aerosol-forming substrate having an average length of from 60 mm to 60 mm, for example from 500 μm to 30 mm, for example from 1000 μm to 10000 μm.

Example Ex 118. The combined aerosol-forming substrate of any of Examples Ex 105 to Ex 117, wherein the second material comprises thermally conductive particles.

Example Ex 119. The combined aerosol-forming substrate of any of Examples Ex 105 to Ex 118, wherein the second material comprises 1% to 50% by dry weight of thermally conductive particles.

Example Ex 120. The method of any one of Examples Ex 105 to Ex 119, wherein the second material comprises thermally conductive particles formed of a thermally conductive material selected from the list consisting of carbon, graphite, expanded graphite, graphene and metal. A combined aerosol-forming substrate comprising:

Example Ex 121. The method of any one of Examples Ex 105 to Ex 120, wherein the second material is a thermally conductive material selected from the list consisting of carbon, graphite, expanded graphite, graphene, and metal, for example A combined aerosol-forming substrate, wherein each discontinuous element of the second material is a strip of metal foil or carbon foil, for example copper foil, or aluminum foil, or stainless steel foil, or graphite foil.

Example Ex 122. The method of any of Examples Ex 105 through Ex 121, wherein the first material has a thermal conductivity of less than 0.2 W/(mK) at 25°C and the second material has a thermal conductivity of less than 0.1 W/(mK) at 25°C. , 0.22, 0.3, 0.5, 1, 2, 5, 10, 20, 50, 100, 200, 500, 1000, 1500, or 1700 W/(mK).

Example Ex 123. The method according to any one of Examples Ex 105 to Ex 122, wherein the first material is configured to generate an aerosol when heated, for example when heated to a temperature of 120°C to 395°C, A combined aerosol-forming substrate, wherein the second material is not configured to generate an aerosol when heated, for example when heated to a temperature of 120°C to 350°C.

Example Ex 124. The method of any one of Examples Ex 105 to Ex 123, wherein both the first material and the second material form an aerosol when heated, for example when heated to a temperature of 120°C to 395°C. A combined aerosol-forming substrate configured to generate electricity.

Example Ex 125. The combined aerosol-forming substrate of any one of Examples Ex 105 to Ex 124, wherein the first material comprises tobacco, for example the first material is formed from homogenized tobacco.

Example Ex 126. The method of any one of Examples Ex 105 to Ex 125, wherein the first material comprises tobacco and an aerosol former and is configured to generate an aerosol when heated to a temperature of 120°C to 395°C. A combined aerosol-forming substrate comprising:

Example Ex 127. The combined aerosol-forming substrate of Example Ex 126, wherein the first material is a homogenized tobacco material and further comprises fibers and a binder.

Example Ex 128. The method of any one of Examples Ex 105 to Ex 127, wherein the second material comprises an aerosol former and conductive particles constituting from 3% to 90% by weight of the second material on a dry weight basis. and wherein the second material is configured to generate an aerosol when heated to a temperature of 120°C to 395°C.

Example Ex 129. The method of any of Examples Ex 105 to Ex 128, wherein said second material comprises tobacco and an aerosol former and conductive particles constituting from 3% to 90% by weight of said second material on a dry weight basis. wherein the second material is configured to generate an aerosol when heated to a temperature of 120°C to 395°C.

Example Ex 130. The combined aerosol-forming substrate of Example Ex 129, wherein the second material is a thermally conductive homogenized tobacco material and further comprises fibers and a binder.

Example Ex 131. The method of Example Ex 128, wherein the second material does not comprise tobacco, for example, wherein the second material is a thermally conductive tobacco-free material, and further comprises fibers and a binder. Aerosol-forming substrate.

Example Ex 132. The method of any one of Examples Ex 105 to Ex 131, wherein the discontinuous elements of the first material and the discontinuous elements of the second material are formed separately and mixed together in a predetermined ratio to form the combined A combined aerosol-forming substrate to form an aerosol-forming material.

Example Ex 133. The method of any one of Examples Ex 105 to Ex 132, wherein the ratio of the first material to the second material in the combined aerosol-forming substrate is from 1:10 to 10:1, for example 1: 5 to 8:1, for example 1:1 to 5:1.

Example Ex 134. The process of any one of Examples Ex 105 through Ex 133, wherein the second material is 40 to 80% by weight, on a dry weight basis, a particulate carbon material; 10 to 40% by weight of aerosol former; 4 to 20% by weight fiber; and 2 to 10 weight percent of a binder, wherein the particulate carbon material consists of one or more of graphite, expanded graphite, graphene, carbon nanotubes, and charcoal.

Example Ex 135. The method of any one of Examples Ex 105 through Ex 134, wherein the first material comprises, on a dry weight basis: 40 to 80% by weight of a particulate carbon material; 10 to 40% by weight of aerosol former; 4 to 20% by weight fiber; and 2 to 10 weight percent of a binder, wherein the particulate carbon material consists of one or more of graphite, expanded graphite, graphene, carbon nanotubes, char, and the first material has a lower molecular weight than the second material. A combined aerosol-forming substrate with thermal conductivity.

Example Ex 136. The combined aerosol-forming substrate of Example Ex 135, wherein the particulate carbon material consists of graphite.

Example Ex 137. The combined aerosol-forming substrate according to any one of Examples Ex 105 to Ex 136, wherein the second material and the first material are homogeneously distributed within the combined aerosol-forming substrate.

Example Ex 138. A method of forming a combined aerosol-forming substrate, for example a combined aerosol-forming substrate according to any one of Examples Ex 105 to Ex 137, comprising forming a first plurality of discontinuous elements from a first material. steps; forming a second plurality of discontinuous elements from a second material, and combining the first plurality of discontinuous elements with the second plurality of discontinuous elements to form the combined aerosol-forming substrate, The method of claim 2, wherein the two materials have a greater thermal conductivity than the first material.

Example Ex 139. A method of forming a combined aerosol-forming substrate, for example a combined aerosol-forming substrate according to any one of Examples Ex 105 to Ex 137, comprising providing a first plurality of discontinuous elements from a first material. steps; providing a second plurality of discontinuous elements from a second material, and combining the first plurality of discontinuous elements with the second plurality of discontinuous elements to form the combined aerosol-forming substrate, The method of claim 2, wherein the two materials have a greater thermal conductivity than the first material.

Example Ex 140. The method of Example Ex 138 or Ex 139, wherein the first plurality of discontinuous elements are formed by cutting a sheet of the first material into strips and the second plurality of discontinuous elements are formed by cutting a sheet of the first material into strips. Formed by cutting a sheet into strips.

Example Ex 141. The method of Example Ex 140, wherein the first plurality of discontinuous elements and the second plurality of discontinuous elements are cut to substantially the same size.

Example Ex 142. The method of any one of Examples Ex 138 to Ex 141, wherein forming at least one of the first plurality of discontinuous elements and the second plurality of discontinuous elements comprises, for example, crimping a discontinuous element, the second plurality of discontinuous elements, or both the first and second plurality of discontinuous elements to be crimped elements.

Example Ex 143. The method of any of Examples Ex 138 through Ex 142, comprising forming the first material, forming the second material, or forming both the first and second materials. A method further comprising:

Example Ex 144. The method of any of Examples Ex 138 to Ex 143, wherein the combined aerosol-forming substrate is a combined aerosol-forming substrate as described in connection with any of Examples Ex 105 to Ex 137. .

Example Ex 145. An aerosol-generating article comprising a combined aerosol-forming substrate as defined in any of Examples Ex 105 to Ex 137 or prepared by any of the methods defined in Examples Ex 138 to Ex 144. .

Example Ex 146. The aerosol-generating article of Example Ex 145, wherein the article is in the form of a rod and comprises a plurality of components, including a combined aerosol-forming substrate, assembled within a wrapper or casing.

Example Ex 147. An aerosol-generating article comprising an aerosol-forming substrate according to any of the previous examples and a combined aerosol-forming substrate.

Example Ex 148. The aerosol-generating article of any of the previous examples, wherein the aerosol-generating article comprises a front plug.

Example Ex 149. The aerosol-generating article according to any of Examples Ex 147 to Ex 148, wherein the aerosol-generating article comprises a first hollow tube, for example a first hollow acetate tube.

Example Ex 150. The aerosol-generating article according to any of Examples Ex 147 to Ex 148, wherein the aerosol-generating article comprises a second hollow tube, for example a second hollow acetate tube.

Example Ex 151. The aerosol-generating article of Example Ex 150, wherein the second hollow tube comprises one or more ventilation holes.

Example Ex 152. The aerosol-generating article of any one of Examples Ex 147 to Ex 151, wherein the aerosol-generating article comprises a mouth plug filter.

Example Ex 153. The aerosol-generating article according to any of Examples Ex 147 to Ex 152, wherein the aerosol-generating article comprises a wrapper, for example a paper wrapper.

Example Ex 154. The method of any one of Examples Ex 147 to Ex 153, wherein the aerosol-generating article comprises a front plug, the aerosol-forming substrate is arranged downstream of the front plug, and the first hollow tube comprises: An aerosol-generating article is arranged downstream of an aerosol-forming substrate, wherein a second hollow tube is arranged downstream of the first hollow tube, and a mouth plug filter is arranged downstream of the second hollow tube.

Example Ex 155. The method of Example Ex 154, wherein the front plug, the aerosol-forming substrate, the first hollow tube, the second hollow tube, and the mouth plug filter are surrounded by a wrapper, for example a paper wrapper. , aerosol-generating articles.

Example Ex 156. The method according to any one of Examples Ex 149 to Ex 155 when dependent on Example Ex 148 or Example Ex 148, wherein the front plug is 2 to 10, 3 to 8, or 4 to 6 mm, for example For aerosol-generating articles, having a length of approximately 5 mm.

Example Ex 157. The aerosol-generating article of any of Examples Ex 147 to Ex 156, wherein the aerosol-forming substrate has a length of 5 to 20, 8 to 15, or 10 to 15 mm, for example about 12 mm.

Example Ex 158. The method of any one of Examples Ex 150 to Ex 157 when dependent on Example Ex 149 or Example Ex 149, wherein said first hollow tube has a diameter of 2 to 20, 5 to 15, or 5 to 10 mm, An aerosol-generating article, for example having a length of about 8 mm.

Example Ex 159. The method of any of Examples Ex 151 to Ex 158 when dependent on Example Ex 150 or Example Ex 150, wherein the second hollow tube has a diameter of 2 to 20, 5 to 15, or 5 to 10 mm, An aerosol-generating article, for example having a length of about 8 mm.

Example Ex 160. The method according to any one of Examples Ex 153 to Ex 159 when dependent on Example Ex 152 or Example Ex 152, wherein said mouth plug filter has a diameter of 5 to 20, 8 to 15, or 10 to 15 mm, e.g. An aerosol-generating article, for example having a length of about 12 mm.

Example Ex 161. An aerosol-generating system comprising an aerosol-generating article according to any one of Examples Ex 145 to Ex 160 and an electric aerosol-generating device.

Example Ex 162. The aerosol-generating system of Example EX 161, wherein the electric aerosol-generating device is configured to resistively heat the aerosol-generating article in use.

Example Ex 163. The method of any one of Examples Ex 161 to Ex 162, wherein the electric aerosol-generating device is configured to inductively heat the aerosol-generating article, e.g. the aerosol-forming substrate of the aerosol-generating article, when in use. aerosol generating system.

Example Ex 164. A method of forming an aerosol-forming substrate according to any of the previous examples, for example an aerosol-forming substrate according to any of Examples Ex 1 to Ex 104, comprising:

forming a slurry comprising the thermally conductive particles, the aerosol former, the fiber, and the binder; and

Casting and drying the slurry to form the aerosol-forming substrate or a precursor for forming into the aerosol-forming substrate.

Example Ex 165. The method of Example Ex 164, wherein the slurry comprises water.

Example Ex 166. The method of any of Examples Ex 164 to Ex 165, wherein the slurry comprises 40 to 90, 40 to 85, 50 to 80, 60 to 80, 60 to 75 weight percent water.

Example Ex 167. The method of any of Examples Ex 164 through Ex 166, wherein the slurry comprises an acid such as fumaric acid.

Example Ex 168. The method of any of Examples Ex 164 through Ex 167, wherein the slurry comprises nicotine.

Example Ex 169. The process of any of Examples Ex 164 through Ex 168, wherein forming the slurry comprises:

Forming a first mixture, wherein the first mixture is:

The aerosol former;

the fiber;

water;

Optionally, the acid; and

optionally comprising said nicotine;

forming a second mixture, wherein the second mixture includes:

The thermally conductive particles; and

comprising the binder,

and adding the second mixture to the first mixture to form a combined mixture.

Example Ex 170. The method of Example Ex 170, wherein forming the first mixture comprises providing the aerosol former or a solution comprising the aerosol former and the nicotine.

Example Ex 171. The method of Example Ex 171, wherein forming the first mixture comprises adding the acid to the aerosol former or a solution comprising the aerosol former and the nicotine to form the first premixture. A method comprising steps.

Example Ex 172. The method of any of Examples Ex 170 to Ex 171, wherein forming the first mixture comprises adding the water to the aerosol former or to the solution comprising the aerosol former and the nicotine or , adding to the first premixture to form a second premixture.

Example Ex 173. The method of any of Examples Ex 169 through Ex 172, wherein forming the first mixture comprises adding the fibers to the second premixture.

Example Ex 174. The method of any of Examples Ex 169 through Ex 173, wherein forming the second mixture comprises mixing the thermally conductive particles and the binder.

Example Ex 175. The method of any of Examples Ex 169 through Ex 174, wherein the method comprises first mixing the combined mixture.

Example Ex 176. The method of Example Ex 175, wherein the first mixing occurs under a first pressure of less than or equal to 500, 400, 300, 250, or 200 mbar.

Example Ex 177. The method of Example Ex 175 or Ex 176, wherein the first mixing occurs for 1 to 10, 2 to 8, or 3 to 6 minutes, for example about 4 minutes.

Example Ex 178. The method of any of Examples Ex 175 through Ex 177, wherein the method comprises mixing the first mixture followed by a second mixing.

Example Ex 179. The method of Example Ex 178, wherein the second mixing occurs under a second pressure that is less than the first pressure.

Example Ex 180. The method of Example Ex 179, wherein the second pressure is less than or equal to 500, 400, 300, 200, 150, or 100 mbar.

Example Ex 181. Example Ex 178 or Ex 179 or Ex 180, wherein the second mixing occurs for 5 to 120, 5 to 80, 5 to 40, or 10 to 30 seconds, for example about 20 seconds. , method.

Example Ex 182. The method of any of Examples Ex 164 to Ex 181, wherein casting the slurry comprises casting the slurry onto a flat support, for example a steel flat support.

Example Ex 183. The method of any of Examples Ex 164 to Ex 182, wherein after casting the slurry and before drying the slurry, the method further comprises establishing a thickness of the slurry, e.g. A method comprising setting the thickness to 100 to 1,000, 200 to 900, 300 to 800, 500 to 700 μm, for example about 600 μm.

Example Ex 184. The method of any of Examples Ex 164 through Ex 183, wherein drying the slurry comprises providing a flow of a gas, such as air, over or through the slurry.

Example Ex 185. The method of Example Ex 184, wherein the stream of gas is heated.

Example Ex 186. The method of Example Ex 185, wherein the stream of gas is heated to a temperature of 100 to 160°C, or 120 to 140°C.

Example Ex 187. The method of any of Examples Ex 184 to Ex 186, wherein the flow of gas is provided for 1 to 10 or 2 to 5 minutes.

Example Ex 188. The method of any of Examples Ex 164 through Ex 187, wherein the step of drying the slurry is such that the slurry has a moisture content of 1 to 20, 2 to 15, 2 to 10, or 3 to 7 weight percent. drying the slurry until it has

Example Ex 189. The method of any of Examples Ex 164 through Ex 188, wherein drying the slurry forms a precursor for forming into the aerosol-forming substrate, wherein the precursor is a sheet of aerosol-forming material.

Example Ex 190. The method of Example Ex 189, wherein the method comprises cutting a sheet of the aerosol-forming material.

Now, the embodiment will be further described with reference to the drawings.
1 shows a schematic cross-sectional view of a first embodiment of an aerosol-generating article;
Figure 2 shows a schematic cross-sectional view of a second embodiment of the aerosol-generating article;
Figure 3 shows a schematic cross-sectional view of a first embodiment of an aerosol-generating system;
Figure 4 shows a schematic cross-sectional view of a second embodiment of the aerosol-generating system;
Figure 5 shows a schematic cross-sectional view of a third embodiment of an 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 extends from the upstream or distal end 18 to the downstream or proximal or mouth end 20 and has an overall length of about 45 mm.

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 positioned upstream of the rod 12 of the aerosol-forming substrate.

The downstream section 14 includes a support element 22 positioned immediately downstream of a rod 12 of aerosol-forming 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. Sorted. 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 as a whole is substantially 0 mm 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 26 to the downstream end 32 of the first hollow tubular segment 26. do. The internal cavity 28 is substantially empty, so that a substantially unrestricted airflow is activated along the internal cavity 28 . Accordingly, 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 mm H ₂ O.

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

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 mm H ₂ O.

The second hollow tubular segment 34 has a length of about 8 mm, an outer diameter of about 7.25 mm, and an inner diameter (D _STS ) of about 3.25 mm. Accordingly, the thickness of the peripheral wall of the second hollow tubular segment 34 is approximately 2 mm. 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, a ventilation zone is provided approximately 2 mm 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 , downstream section 14 further comprises a mouthpiece element 42 , also referred to as a mouth plug filter, positioned downstream of 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 mm and an outer diameter of approximately 7.25 mm. The RTD of mouthpiece element 42 is approximately 12 mm 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-forming substrate has an outer diameter of approximately 7.25 mm and a length of approximately 12 mm.

The upstream section 16 includes an upstream element 46, also referred to as a forward plug, located immediately upstream of a rod 12 of the aerosol-forming substrate, the upstream element 46 being longitudinally connected to the rod 12. It is sorted by . 1, the downstream end of the upstream element 46 abuts the upstream end of the rod 12 of the aerosol-forming 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 mm. The RTD of the upstream element 46 is approximately 30 mm 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.

l GmbH, AMG Graphite GK로부터의 FP 99,5(>99.5% 순도) 그래파이트 입자이지만, 다른 입자들 또는 입자들의 혼합물들이 사용될 수 있다. 각각의 열 전도성 입자는 25°C에서 적어도 한 방향으로 약 6W/(mK)의 열 전도성을 갖는다.The rod 12 of the aerosol-forming substrate contains about 76.1% by weight of thermally conductive particles 44 on a dry weight basis. In this embodiment, the thermally conductive particles 44 are graphite particles, especially Graphit Kropfm

FP 99,5 (>99.5% purity) graphite particles from GmbH, AMG Graphite GK, but other particles or mixtures of particles can be used. Each thermally conductive particle has a thermal conductivity of approximately 6 W/(mK) in at least one direction at 25°C.

Rod 12 of aerosol-forming substrate comprises about 17.7% by weight aerosol-forming agent on a dry weight basis. In this embodiment, the aerosol former is glycerol, especially ICOF European food grade (>99.5% purity) glycerol.

Rod 12 of the aerosol-forming substrate comprises about 3.9% fibers by weight on a dry weight basis. In this embodiment, the fiber is cellulosic fiber, especially birch cellulose fiber from Stora Enso OYJ.

The rod 12 of the aerosol-forming substrate includes about 2.3% by weight binder on a dry weight basis. In this embodiment, the binder is guar gum, specifically guar gum from Gumix International Inc.

The rod 12 of aerosol-forming substrate contains approximately 10% water by weight when measured at 25°C.

In another embodiment, the rod 12 of the aerosol-forming substrate further comprises one or more of nicotine, an acid such as fumaric acid, a plant such as clove or rosmarinus, and a flavoring agent.

The aerosol-forming substrate has a thermal conductivity of at least 0.1 W/(mK) in at least one direction at 25°C. The aerosol-forming substrate may have a thermal conductivity of 0.2, 0.5, 1, 1.5 or more W/(mK) in at least one direction at 25°C.

Each of the thermally conductive particles 44 is substantially spherical in shape. The thermally conductive particles 44 are distributed substantially homogeneously throughout the aerosol-forming substrate. The particle size distribution has a volumetric D10 particle size of about 6 μm, a volumetric D50 particle size of about 20 μm, and a volumetric D90 particle size of about 56 μm. Each of the thermally conductive particles 44 has a particle size of greater than about 1 μm and less than about 300 μm.

The thermally conductive particles 44 have a density of approximately 2200 kg/m3. The aerosol-forming substrate has a density of approximately 800 kg/m3.

The rod 12 of the aerosol-forming substrate is formed by a process described later.

A slurry is formed using a lab 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 the wrap disperser. These first ingredients are then mixed for 5 minutes at 600 to 700 rpm at 25°C to ensure a homogeneous mixture and hydrate the fibers. A second mixture is then formed by manually mixing about 32.95 g of thermally conductive particles and about 0.92 g of binder. This mixing of the second mixture avoids 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 at 25°C and a first reduced pressure of approximately 200 mbar. Depressurization can help ensure that the thermally conductive particles are homogeneously dispersed within the mixture and that there is little air trapped and almost no clumps in the combined mixture. The combined mixture is then mixed at 5000 rpm for 20 seconds at 25°C and a second reduced pressure of approximately 100 mbar. This second decompression can help remove any remaining air bubbles. This forms a slurry for casting.

The slurry is then cast and dried using appropriate equipment. In this implementation, the commercially available Labcoater Mathis device is used. The device includes stainless steel, a 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 mm. This ensures that the thickness of the slurry is less than 0.6 mm at any given point.

The slurry is then dried with hot air at 120°C to 140°C for 2 to 5 minutes. After this drying, a sheet of aerosol-forming substrate is formed. This sheet has a thickness of approximately 159 μm, a basis weight of approximately 125.7 g/m 2 , and a density of approximately 0.79 kg/m 3 .

The sheet is then pleated and cut to form rods 12 of the aerosol-forming substrate. In another embodiment, the sheet is also crimped.

After forming the rod 12 of the aerosol-forming substrate, the aerosol-generating article 10 is assembled by positioning the various components of the article 10 and wrapping the components in a wrapper 70.

Figure 2 shows a schematic cross-sectional view of a second embodiment of the aerosol-generating article 11. This second embodiment is identical to the first embodiment of Figure 1 except that the rods 12 of aerosol-forming substrates are replaced by alternative rods 13 of combined aerosol-forming substrates. Identical reference numerals have been used for identical components in the embodiments of FIGS. 1 and 2 .

In the rod 13 of the second embodiment, the combined aerosol-forming substrate includes a first material and a second material. A first material is included in the combined aerosol-forming substrate as a first plurality of discontinuous elements, and a second material is included in the combined aerosol-forming substrate as a second plurality of discontinuous elements. In this embodiment, the first material and the second material are equally abundant by weight in the combined aerosol-forming substrate. However, in other embodiments, more or less of the first material may be present in the combined aerosol-forming substrate than the second material.

In this embodiment, the elements of both the first and second pluralities of discontinuous elements have an average thickness of 150 μm to 300 μm, an average width of 600 μm to 1000 μm, and an average length of 1000 μm to 10000 μm.

The first material may be conventional tobacco cut filler. As such, the first material may be formed by conventional tobacco cut filler manufacturing processes and may include aerosol formers, fibers and binders, but does not include any thermally conductive particles. As an example, the first material can be prepared using a similar method as presented above for the rod 12 of the aerosol-forming substrate of the first embodiment of Figure 1, except that no thermally conductive particles are included, and the rod Rather than crimping and cutting the sheets to form (12), the sheets are shredded to form reconstituted cut sheets.

The second material is formed of an aerosol-forming substrate similar to that of rod 12 in the first embodiment of FIG. 1 . The second material includes, on a dry weight basis, about 76.1% thermally conductive particles 45, about 17.7% aerosol former, about 3.9% fiber, and about 2.3% binder. In the second material, the thermally conductive particles are all graphite particles or expanded graphite particles, but other particles or mixtures of particles may be used.

The first material has a first thermal conductivity and the second material has a second thermal conductivity that is at least 10% greater than the first thermal conductivity. Accordingly, the second material helps increase the thermal conductivity of the combined aerosol-forming substrate.

Rods 13 of combined aerosol-forming substrates are formed by the process described below.

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 the wrap disperser. These first ingredients are then mixed for 5 minutes at 600 to 700 rpm at 25°C to ensure a homogeneous mixture and hydrate the fibers. A second mixture is then formed by manually mixing about 32.95 g of thermally conductive particles and about 0.92 g of binder. This mixing of the second mixture avoids 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 at 25°C and a first reduced pressure of approximately 200 mbar. Depressurization can help ensure that the thermally conductive particles are homogeneously dispersed within the mixture and that there is little air trapped and almost no clumps in the combined mixture. The combined mixture is then mixed at 5000 rpm for 20 seconds at 25°C and a second reduced pressure of approximately 100 mbar. This second decompression can help remove any remaining air bubbles. This forms a slurry for casting.

The slurry is then cast and dried using appropriate equipment. In this implementation, the commercially available Labcoater Mathis device is used. The device includes stainless steel, a 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 mm. This ensures that the thickness of the slurry is less than 0.6 mm at any given point.

The slurry is then dried with hot air at 120°C to 140°C for 2 to 5 minutes. After this drying, a sheet of aerosol-forming substrate is formed. This sheet has a thickness of approximately 159 μm, a basis weight of approximately 125.7 g/m 2 , and a density of approximately 0.79 kg/m 3 .

The sheet is then broken to form a plurality of discrete elements of the aerosol-forming substrate. That is, the sheet is then cut to form a second material present in the combined aerosol-forming substrate as a second plurality of discontinuous elements.

This second material is then mixed with a first material that is a discontinuous element of the first plurality. As described above, the first material may be formed using conventional tobacco cut filler manufacturing processes. Therefore, it is not explained in detail here.

The mixed first and second materials, present as a plurality of discontinuous elements, are then formed within a rod 13 of the combined aerosol-forming substrate, for example by surrounding it in a wrapper.

Then, after forming the rod 13 of the combined aerosol-forming substrate, the aerosol-generating article 11 is assembled by positioning the various components of the article 11 and wrapping the components in a wrapper 70.

Figure 3 shows a schematic cross-sectional view of a first embodiment of an aerosol-generating system 100. System 100 includes aerosol-generating device 102 and aerosol-generating article 10 of FIG. 1, although device 102 could equally be used with aerosol-generating article 11 of FIG. 2.

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 base of the cavity.

In this implementation, the heating blades 108 include a substrate and an electrical resistance track positioned 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. 3 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 the 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 thermally conductive particles 44 have a significantly higher thermal conductivity than the surrounding aerosol forming material. As such, these particles can act as localized hot-spots and provide a more uniform temperature across the aerosol-forming substrate, especially radially from the heating blades 108 where prior art substrates may have significant temperature gradients. can be provided. 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 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 4 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. 2, although device 202 could be used equivalently with aerosol-generating article 10 of FIG. 1.

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

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

In use, the user inserts the article 11 into the cavity. Figure 4 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 significantly 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 inductor coil 208. This causes the inductor coil 208 to generate a fluctuating electromagnetic field. A rod 13 of combined aerosol-forming substrate is positioned within this fluctuating electromagnetic field. The material of particles 45, graphite and expanded graphite, is a susceptor material. Accordingly, the fluctuating electromagnetic field causes eddy currents in the particle 45. This causes the particles 45 to heat up, which also causes the adjacent aerosol-forming material to heat up.

Heating the aerosol-forming material causes the aerosol-forming material to release volatile compounds. These compounds are entrained by 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 5 shows a schematic cross-sectional view of a third embodiment of an aerosol-generating article 510. This third 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 5 .

Rod 512 of the aerosol-forming substrate of the third embodiment of Figure 5 includes an elongated susceptor element 580.

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. 5 , 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 5, the susceptor element 580 is provided in the form of a strip of ferromagnetic steel and has a length of approximately 12 mm, a thickness of approximately 60 μm, and a width of approximately 4 mm.

The aerosol-generating article 510 of FIG. 5 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.

l GmbH, AMG Graphite GK로부터 상업적으로 이용 가능한 FP 99,5(>99.5% 순도) 그래파이트 입자들이지만, 다른 입자들 또는 입자들의 혼합물들이 사용될 수 있다. 각각의 열 전도성 입자는 25°C에서 적어도 한 방향으로 약 6W/(mK)의 열 전도성을 갖는다.Rod 512 of aerosol-forming substrate contains approximately 66% by weight of thermally conductive particles 44 on a dry weight basis. In this embodiment, the thermally conductive particles 44 are graphite particles, specifically Graphit Kropfm

FP 99,5 (>99.5% purity) graphite particles are commercially available from l GmbH, AMG Graphite GK, but other particles or mixtures of particles may be used. Each thermally conductive particle has a thermal conductivity of approximately 6 W/(mK) in at least one direction at 25°C.

Rod 512 of the aerosol-forming substrate includes about 20% by weight aerosol-forming agent on a dry weight basis. In this embodiment, the aerosol former is glycerol, specifically commercially available ICOF European food grade (>99.5% purity) glycerol.

Rod 512 of the aerosol-forming substrate comprises approximately 7% fibers by weight on a dry weight basis. In this embodiment, the fiber is a cellulosic fiber, particularly birch cellulose fiber, commercially available from Stora Enso OYJ.

Rod 512 of the aerosol-forming substrate contains about 4% binder by weight on a dry weight basis. In this embodiment, the binder is sodium carboxymethyl cellulose, specifically sodium carboxymethyl cellulose (CMC) type K-700, commercially available from Gumix International Inc.

Rod 512 of the aerosol-forming substrate contains approximately 1% nicotine by weight on a dry weight basis.

Rod 512 of the aerosol-forming substrate contains about 2% by weight acid on a dry weight basis. In this embodiment, the acid is fumaric acid, specifically fumaric acid (>99% purity), commercially available from Sigma-Aldrich.

In another embodiment, the substrate further comprises at least one plant, such as clove or rosmarinus.

The rod 12 of aerosol-forming substrate contains approximately 10% water by weight when measured at 25°C.

The aerosol-forming substrate has a thermal conductivity of at least 0.1 W/(mK) in at least one direction at 25°C. The aerosol-forming substrate may have a thermal conductivity of 0.2, 0.5, 1, 1.5 or more W/(mK) in at least one direction at 25°C.

The thermally conductive particles 44 are identical to the particles in the rod 12 of the first embodiment of FIG. 1 .

The rod 512 of the aerosol-forming substrate is formed by a process described later.

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 a slurry, the first mixture is about 12 g of a solution of nicotine in glycerin (aerosol former) at a concentration of 10%, then about 13.2 g of glycerin, then about 2.4 g of fumaric acid, then about 280 g of water, then It is formed by adding approximately 8.4 g of fiber to a lab disperser. These first ingredients are then mixed for 5 minutes at 600 to 700 rpm at 25°C to ensure a homogeneous mixture and hydrate the fibers. A second mixture is then formed by manually mixing about 79.2 g of thermally conductive particles and about 4.8 g of binder. This mixing of the second mixture avoids 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 at 25°C and a first reduced pressure of approximately 200 mbar. Depressurization can help ensure that the thermally conductive particles are homogeneously dispersed within the mixture and that there is little air trapped and almost no clumps in the combined mixture. The combined mixture is then mixed at 5000 rpm for 20 seconds at 25°C and a second reduced pressure of approximately 100 mbar. This second decompression can help remove any remaining air bubbles. This forms a slurry for casting.

The slurry is then cast and dried using appropriate equipment. In this implementation, the commercially available Labcoater Mathis device is used. The device includes stainless steel, a 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 mm. This ensures that the thickness of the slurry is less than 0.6 mm at any given point.

The slurry is then dried with hot air at 120°C to 140°C for 2 to 5 minutes. After this drying, a sheet of aerosol-forming substrate is formed. This sheet has a thickness of approximately 230 μm and a basis weight of approximately 200 g/m2.

The sheet is then crimped and cut to form a substantially rod-shaped precursor. A susceptor element is then inserted into the precursor to form a rod 512 of aerosol-forming substrate.

After forming the rod 512 of the aerosol-forming substrate, the aerosol-generating article 510 is assembled by positioning the various components of the article 510 and wrapping the components in a wrapper 70.

For the purposes of this description and the appended claims, except where otherwise indicated, all numbers expressing quantities, 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 may 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)

As an aerosol-forming substrate, on a dry weight basis,
10 to 90% by weight of carbon particles;
7 to 60% by weight of aerosol former;
2 to 20% by weight fiber; and
comprising 2 to 10% by weight of a binder,
An aerosol-forming substrate, wherein each of the carbon particles consists of one or more of graphite, expanded graphite, graphene, carbon nanotubes, charcoal, and diamond. 2. The aerosol-forming substrate of claim 1, wherein the carbon particles have a particle size distribution with a volume D10 particle size of 1 to 20 μm. 3. An aerosol-forming substrate according to claim 1 or 2, wherein the carbon particles have a particle size distribution with a volumetric D90 particle size of 50 to 300 μm. 4. The method of any one of claims 1 to 3, wherein the carbon particles have a particle size distribution having a volume D10 particle size and a number D90 particle size, wherein the volume D90 particle size is less than or equal to 50 times the number D10 particle size. , aerosol-forming substrate. 5. An aerosol-forming substrate according to any preceding claim, wherein some or all of the carbon particles are substantially spherical. 6. An aerosol-forming substrate according to any preceding claim, wherein each carbon particle consists of one or more of expanded graphite, graphene and diamond. 7. An aerosol-forming substrate according to any preceding claim, wherein the substrate comprises at least 40% by weight of carbon particles on a dry weight basis. 8. An aerosol-forming substrate according to any preceding claim, wherein the substrate comprises at least 60% by weight of carbon particles on a dry weight basis. 9. An aerosol-forming substrate according to any preceding claim, wherein the carbon particles are distributed substantially homogeneously throughout the aerosol-forming substrate. 10. An aerosol-forming substrate according to any one of claims 1 to 9, wherein the aerosol-forming substrate is a tobacco-free aerosol-forming substrate. 11. An aerosol-forming substrate according to any preceding claim, wherein the aerosol-forming substrate comprises 1 to 20% by weight water. A combined aerosol-forming substrate comprising:
Comprising a first material and a second material, wherein the first material is included in the combined aerosol-forming substrate as a first plurality of discontinuous elements, and the second material is a second plurality of discontinuous elements and is included in the combined aerosol-forming substrate. Included in the description,
the first material comprises an aerosol former and has a first thermal conductivity;
The second material comprises an aerosol-forming substrate according to any one of claims 1 to 11 or is an aerosol-forming substrate according to any one of claims 1 to 11 and has a thermal conductivity greater than the first thermal conductivity. A combined aerosol-forming substrate having a second thermal conductivity. An aerosol-generating article comprising an aerosol-forming substrate according to any one of claims 1 to 11 and a combined aerosol-forming substrate according to claim 12. An aerosol-generating system comprising an aerosol-generating article according to claim 13 and an electric aerosol-generating device for heating the aerosol-forming substrate of the aerosol-generating article or a combined aerosol-forming substrate. 12. A method of forming an aerosol-forming substrate according to any one of claims 1 to 11 or a combined aerosol-forming substrate according to claim 12, comprising:
forming a slurry comprising the carbon particles, the aerosol former, the fiber, and the binder; and
Casting and drying the slurry to form the aerosol-forming substrate or a precursor for forming into the aerosol-forming substrate.