Improved aerosol-forming subtrate

Patent metadata

Field	Value
Publication number	US-2025040586-A1
Application number	US-202218576790-A
Country	US
Kind code	A1
Filing date	Jul 7, 2022
Priority date	Jul 7, 2021
Publication date	Feb 6, 2025
Grant date	—

Abstract

There is provided an aerosol-forming substrate comprising, on a dry weight basis: between 10 and 90 wt % carbon particles; between 7 and 60 wt % of an aerosol former; between 2 and 20 wt % of fibres; and between 2 and 10 wt % of a binder. Each of the carbon particles consists of one or more of graphite, expanded graphite, graphene, carbon nanotubes, charcoal, and diamond. There is also provided an aerosol-generating article comprising the aerosol-forming substrate and a method of forming the aerosol-forming substrate.

First claim

1 . An aerosol-forming substrate comprising, on a dry weight basis:
between 70 and 90 wt % carbon particles; between 7 and 26 wt % of an aerosol former; between 2 and 20 wt % of fibres; and between 2 and 10 wt % of a binder,
wherein each of the carbon particles consists of one or more of graphite, expanded graphite, graphene, carbon nanotubes, charcoal, and diamond.

2 . An aerosol-forming substrate according to claim 1 , wherein the carbon particles have a particle size distribution having a volume D10 particle size between 1 and 20 microns.

3 . An aerosol-forming substrate according to claim 1 , wherein the carbon particles have a particle size distribution having a volume D90 particle size between 50 and 300 microns.

4 . An aerosol-forming substrate according to claim 1 , 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 no more than 50 times the number D10 particle size.

5 . An aerosol-forming substrate according to claim 1 , wherein some or all of the carbon particles are substantially spherical.

6 . An aerosol-forming substrate according to claim 1 , wherein each of the carbon particles consists of one or more of expanded graphite, graphene, and diamond.

7 . An aerosol-forming substrate according to claim 1 , wherein the substrate comprises, on a dry weight basis, at least 75 wt % of the carbon particles.

8 . An aerosol-forming substrate according to claim 1 , wherein the substrate comprises, on a dry weight basis, at least 80 wt % of the carbon particles.

9 . An aerosol-forming substrate according to claim 1 , wherein the carbon particles are substantially homogeneously distributed throughout the aerosol-forming substrate.

10 . An aerosol-forming substrate according to claim 1 , wherein the aerosol-forming substrate is a tobacco-free aerosol-forming substrate.

11 . An aerosol-forming substrate according to claim 1 , wherein the aerosol-forming substrate comprises between 1 and 20 wt % water.

12 . A combined aerosol-forming substrate comprising:
a first material and a second material, the first material being comprised in the combined aerosol-forming substrate as a first plurality of discrete elements and the second material being comprised in the combined aerosol-forming substrate as a second plurality of discrete elements, in which the first material comprises an aerosol former and has a first thermal conductivity, and in which the second material comprises, or is, an aerosol-forming substrate according to claim 1 and has a second thermal conductivity that is greater than the first thermal conductivity.

13 . An aerosol-generating article comprising an aerosol-forming substrate according to claim 1 .

14 . An aerosol-generating system comprising an aerosol-generating article according to claim 13 and an electrical aerosol-generating device for heating the aerosol-forming substrate.

15 . A method of forming an aerosol-forming substrate according to claim 1 , the method comprising:
forming a slurry comprising the carbon particles, the aerosol former, the fibres, 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.

16 . An aerosol-generating article comprising an aerosol-forming substrate according to the combined aerosol-forming substrate according to claim 12 .

17 . An aerosol-generating system comprising an aerosol-generating article according to claim 16 and an electrical aerosol-generating device for heating the combined aerosol-forming substrate of the aerosol-generating article.

18 . A method of forming a combined aerosol-forming substrate according to claim 12 , the method comprising:
forming a slurry comprising the carbon particles, the aerosol former, the fibres, 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.

Assignees

• Philip Morris Products Sa

Inventors

• Fedeli Francesco
• Wairimu Esther
• Huang Houxue
• Ajithkumar Anu
• Van Den Boogaart Marc Antonius Friedrich
• Dupasquier Yan

Classifications

• A24B15/14 Primary

  made of tobacco and a binding agent not derived from tobacco · CPC title

• A24F40/46

  Shape or structure of electric heating means · CPC title

• A24D1/20

  Cigarettes specially adapted for simulated smoking devices · CPC title

• A24B15/285

  characterised by structural features, e.g. particle shape or size · CPC title

• A24B15/42

  by organic and inorganic substances {(A24B15/281 takes precedence)} · CPC title