Aerosol-forming substrate with improved thermal conductivity

Abstract

An aerosol-forming substrate for a heatable aerosol-generating article is provided, the aerosol-forming substrate including an aerosol-forming material and between 0.1 and 15 weight percent carbon particles, the carbon particles having a volume mean particle size of greater than 10 microns, the carbon particles having a particle size distribution having a D10 particle size and a D90 particle size, and the D90 particle size being less than 20 times the D10 particle size. A method of forming the aerosol-forming substrate, and an aerosol-generating article including the aerosol-forming substrate, are also provided.

1 .- 15 . (canceled) 
     
     
         16 . An aerosol-forming substrate for a heatable aerosol-generating article, the aerosol-forming substrate comprising:
 an aerosol-forming material and between 0.1 and 15 weight percent carbon particles,   wherein the carbon particles have a volume mean particle size of greater than 10 microns,   wherein the carbon particles have a particle size distribution having a D10 particle size and a D90 particle size, and   wherein the D90 particle size is less than 20 times the D10 particle size.   
     
     
         17 . The aerosol-forming substrate according to  claim 16 , wherein the carbon particles consist of one or more of: graphite particles, expanded graphite particles, and graphene particles. 
     
     
         18 . The aerosol-forming substrate according to  claim 16 , wherein the aerosol-forming material comprises an organic material, an aerosol-former, and a binder. 
     
     
         19 . The aerosol-forming substrate according to  claim 16 ,
 wherein the aerosol-forming material is in a form of one or more of: cut-filler, powder particles, granules, pellets, shreds, spaghettis, strips, or sheets, and   wherein the carbon particles have a volume mean particle size of between 10 and 1,000 microns.   
     
     
         20 . The aerosol-forming substrate according to  claim 16 , wherein the aerosol-forming material is in a form of a gathered sheet and the carbon particles have a volume mean particle size of between 10 microns and 200 microns. 
     
     
         21 . The aerosol-forming substrate according to  claim 20 , wherein the carbon particles have a volume mean particle size of between 30 microns and 150 microns. 
     
     
         22 . The aerosol-forming substrate according to  claim 16 , wherein the aerosol-forming substrate has a thermal conductivity of greater than 0.06 W/mK in at least one direction. 
     
     
         23 . The aerosol-forming substrate according to  claim 16 , wherein the aerosol-forming substrate has a density of less than 1,000 kg/m 3 . 
     
     
         24 . The aerosol-forming substrate according to  claim 16 , wherein the carbon particles consist of one or both of expanded graphite particles and graphene particles. 
     
     
         25 . The aerosol-forming substrate according to  claim 16 , wherein the carbon particles have a volume mean particle size of between 10 microns and 75 microns. 
     
     
         26 . The aerosol-forming substrate according to  claim 16 , wherein one or both of a volume mean particle size and a D50 particle size of the carbon particles is greater than or equal to 150 microns. 
     
     
         27 . A method of forming an aerosol-forming substrate according to  claim 16 , the method comprising:
 forming a slurry comprising an organic material and carbon particles having a volume mean particle size of greater than 10 microns and a particle size distribution having a D10 particle size and a D90 particle size, wherein the D90 particle size is less than 20 times the D10 particle size;   homogenising the slurry; and   casting and drying the slurry to form the aerosol-forming substrate.   
     
     
         28 . A method of forming an aerosol-forming substrate according to  claim 16 , the method comprising:
 providing an aerosol-forming material; and   coating carbon particles having a volume mean particle size of greater than 10 microns onto the aerosol-forming material to form the aerosol-forming substrate.   
     
     
         29 . An aerosol-generating article comprising an aerosol-forming substrate according to  claim 16 . 
     
     
         30 . An aerosol-generating system comprising an aerosol-generating article according to  claim 29  and an electrical aerosol-generating device configured to heat the aerosol-generating article so as to generate an aerosol.