RU2843439C1 - Aerosol-forming substrate and aerosol-generating article comprising such substrate - Google Patents

Abstract

FIELD: smoking accessories.

SUBSTANCE: group of inventions relates to an aerosol-forming substrate and to an aerosol-generating article. Substrate (1020), forming an aerosol, comprises: one or more substances for forming an aerosol; hydroxypropyl methylcellulose; and one or more reinforcing substances based on cellulose. Aerosol-forming substrate (1020) has an aerosol-forming substance content of more than 30 wt.%. One or more cellulose-based reinforcing substances contain cellulose powder. Aerosol-forming substrate (1020) has cellulose powder content of 0.5–50 wt.%.

EFFECT: providing an increase in the tensile strength of the aerosol-forming substrate, which leads to reduction of its destruction during the corrugation process; and there is also reduction or elimination of crusting during use, especially crusting on the current collector, which can lead to an increased level of nicotine delivered to the user, and to increase the volume of the aerosol generated from the aerosol-forming substrate.

13 cl, 2 dwg, 2 tbl

Description

The present invention relates to an aerosol-forming substrate containing hydroxypropyl methylcellulose and one or more cellulose-based reinforcing agents. The invention also relates to an aerosol-generating article containing said aerosol-forming substrate.

Aerosol generating systems for delivering an aerosol to a user typically include an atomizer configured to generate an inhalable aerosol from an aerosol-forming substrate. Some known aerosol generating systems include a thermal atomizer, such as an electric heater or an induction heating device. The thermal atomizer is designed to heat and vaporize an aerosol-forming substrate to generate an aerosol. Common aerosol-forming substrates for use in aerosol generating systems are nicotine-based formulations, which may be liquid nicotine-based formulations containing an aerosol-forming substance, such as glycerin and/or propylene glycol.

It would be desirable to provide an aerosol generating article having an aerosol generating substrate having an increased tensile strength.

It would also be desirable to provide an aerosol generating article having an aerosol generating substrate that exhibits a reduced tendency to melt and form a crust on a portion of the aerosol generating article or a portion of the aerosol generating system.

An aerosol-forming substrate is provided for use in an aerosol-generating system. The aerosol-forming substrate may contain one or more aerosol-forming substances. The aerosol-forming substrate may contain hydroxypropyl methylcellulose. The aerosol-forming substrate may contain one or more cellulose-based reinforcing agents.

Also provided is an aerosol-forming substrate for use in an aerosol-generating system, wherein the aerosol-forming substrate comprises: one or more aerosol-forming agents; hydroxypropyl methylcellulose; and one or more cellulose-based reinforcing agents.

An aerosol generating article is also provided for use in an aerosol generating system. The aerosol generating article may comprise an aerosol forming substrate. The aerosol forming substrate may comprise one or more aerosol forming substances. The aerosol forming substrate may comprise hydroxypropyl methylcellulose. The aerosol forming substrate may comprise one or more cellulose based reinforcing substances.

Also provided is an aerosol generating article comprising: an aerosol forming substrate comprising: one or more aerosol forming substances; hydroxypropyl methylcellulose; and one or more cellulose-based reinforcing substances.

An aerosol generating system is also provided, comprising an aerosol generating device and an aerosol generating article. The aerosol generating article may comprise an aerosol forming substrate. The aerosol forming substrate may comprise one or more aerosol forming substances. The aerosol forming substrate may comprise hydroxypropyl methylcellulose. The aerosol forming substrate may comprise one or more cellulose-based reinforcing substances.

Also provided is an aerosol generating system comprising: an aerosol generating device; and an aerosol generating article comprising an aerosol forming substrate, wherein the aerosol forming substrate comprises: one or more aerosol forming substances; hydroxypropyl methylcellulose; and one or more cellulose-based reinforcing substances.

As used herein, the term "aerosol-generating article" refers to an article for creating an aerosol. An aerosol-generating article typically comprises an aerosol-forming substrate that is suitable and designed to be heated or burned to release volatile compounds that can form an aerosol. A conventional cigarette is lit when the user applies a flame to one end of the cigarette and draws air through the other end. The localized heat provided by the flame and the oxygen in the air drawn through the cigarette causes the end of the cigarette to ignite, and the resulting combustion generates inhalable smoke. In contrast, in "heated aerosol-generating articles," the aerosol is generated by heating the aerosol-forming substrate rather than by burning the aerosol-forming substrate. Known heated aerosol-generating articles include, for example, electrically heated aerosol-generating articles.

As used herein, the term "aerosol-forming substrate" refers to a substrate that is capable of generating volatile compounds upon heating that can form an aerosol. The aerosol generated from an aerosol-forming substrate may be visible or invisible to the human eye and may contain vapors (e.g., finely dispersed particles of substances that are in a gaseous state and are typically liquid or solid at room temperature), as well as gases and liquid droplets of condensed vapors.

An aerosol-forming substrate that contains a combination of hydroxypropyl methylcellulose and a cellulose-based strengthening agent may have a number of advantages.

Incorporation of hydroxypropyl methylcellulose into an aerosol-forming substrate may help improve the manufacturing process of the aerosol-forming substrate. For example, hydroxypropyl methylcellulose may reduce the overall viscosity of the suspension that is mixed during the manufacture of the aerosol-forming substrate. A suspension with a lower viscosity may flow more easily than conventional suspensions, and a suspension with a lower viscosity may be easier to mix, transfer, and handle during the manufacturing process.

Incorporating a cellulose-based reinforcement into an aerosol-forming substrate can increase the tensile strength of the aerosol-forming substrate. An aerosol-forming substrate with a higher tensile strength may be less likely to deteriorate or break, for example, during transportation or during the manufacturing process.

Despite the above-mentioned advantages, the present inventors have found that an aerosol-forming substrate containing hydroxypropyl methylcellulose may have insufficient tensile strength. However, using a cellulose-based reinforcing agent to increase the tensile strength of the aerosol-forming substrate can overcome the decrease in tensile strength caused by the content of hydroxypropyl methylcellulose, while still providing the above-mentioned processing advantages associated with hydroxypropyl methylcellulose.

The aerosol-forming substrate may have a hydroxypropyl methylcellulose content greater than about 0.5 percent by weight. Advantageously, the present inventors have found that hydroxypropyl methylcellulose can be an effective binder for the aerosol-forming substrate.

The aerosol-forming substrate may have a hydroxypropyl methylcellulose content greater than about 1 percent by weight. The aerosol-forming substrate may have a hydroxypropyl methylcellulose content greater than about 5 percent by weight. The aerosol-forming substrate may have a hydroxypropyl methylcellulose content greater than about 10 percent by weight. The aerosol-forming substrate may have a hydroxypropyl methylcellulose content greater than about 15 percent by weight. The aerosol-forming substrate may have a hydroxypropyl methylcellulose content greater than about 20 percent by weight.

The aerosol-forming substrate may have a hydroxypropyl methylcellulose content of less than about 50 percent by weight. The aerosol-forming substrate may have a hydroxypropyl methylcellulose content of less than about 45 percent by weight. The aerosol-forming substrate may have a hydroxypropyl methylcellulose content of less than about 40 percent by weight. The aerosol-forming substrate may have a hydroxypropyl methylcellulose content of less than about 35 percent by weight. The aerosol-forming substrate may have a hydroxypropyl methylcellulose content of less than about 30 percent by weight. The aerosol-forming substrate may have a hydroxypropyl methylcellulose content of less than about 25 percent by weight. The aerosol-forming substrate may have a hydroxypropyl methylcellulose content of less than about 20 percent by weight.

The aerosol-forming substrate may have a hydroxypropyl methylcellulose content of from about 0.5 percent by weight to about 50 percent by weight. The aerosol-forming substrate may have a hydroxypropyl methylcellulose content of from about 0.5 percent by weight to about 45 percent by weight. The aerosol-forming substrate may have a hydroxypropyl methylcellulose content of from about 0.5 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a hydroxypropyl methylcellulose content of from about 0.5 percent by weight to about 35 percent by weight. The aerosol-forming substrate may have a hydroxypropyl methylcellulose content of from about 0.5 percent by weight to about 30 percent by weight. The aerosol-forming substrate may have a hydroxypropyl methylcellulose content of from about 0.5 percent by weight to about 25 percent by weight. The aerosol-forming substrate may have a hydroxypropyl methylcellulose content of from about 0.5 percent by weight to about 20 percent by weight.

The aerosol-forming substrate may have a hydroxypropyl methylcellulose content of from about 0.5 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a hydroxypropyl methylcellulose content of from about 1 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a hydroxypropyl methylcellulose content of from about 5 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a hydroxypropyl methylcellulose content of from about 10 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a hydroxypropyl methylcellulose content of from about 15 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a hydroxypropyl methylcellulose content of from about 20 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a hydroxypropyl methylcellulose content of from about 25 percent by weight to about 40 percent by weight.

The aerosol-forming substrate may have a hydroxypropyl methylcellulose content of from about 0.5 percent by weight to about 45 percent by weight. The aerosol-forming substrate may have a hydroxypropyl methylcellulose content of from about 1 percent by weight to about 45 percent by weight. The aerosol-forming substrate may have a hydroxypropyl methylcellulose content of from about 1 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a hydroxypropyl methylcellulose content of from about 5 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a hydroxypropyl methylcellulose content of from about 5 percent by weight to about 35 percent by weight. The aerosol-forming substrate may have a hydroxypropyl methylcellulose content of from about 10 percent by weight to about 35 percent by weight. The aerosol-forming substrate may have a hydroxypropyl methylcellulose content of from about 10 percent by weight to about 30 percent by weight. The aerosol-forming substrate may have a hydroxypropyl methylcellulose content of from about 15 percent by weight to about 30 percent by weight. The aerosol-forming substrate may have a hydroxypropyl methylcellulose content of from about 15 percent by weight to about 25 percent by weight. The aerosol-forming substrate may have a hydroxypropyl methylcellulose content of from about 20 percent by weight to about 25 percent by weight.

The hydroxypropyl methylcellulose may be a low viscosity hydroxypropyl methylcellulose. For example, the hydroxypropyl methylcellulose may have a viscosity of 0.05 Pa/s. In some examples, the hydroxypropyl methylcellulose may have a viscosity of 0.015 Pa/s. In some examples, the hydroxypropyl methylcellulose may have a viscosity of 0.015 Pa/s to 0.05 Pa/s.

Advantageously, the present inventors have found that the use of low viscosity hydroxypropyl methylcellulose can provide advantages in the manufacturing process. The use of low viscosity hydroxypropyl methylcellulose can result in the formation of a low viscosity suspension that is easier to mix and move during manufacturing and processing.

The aerosol-forming substrate may have a cellulose-based reinforcement content greater than about 0.5 percent by weight. The aerosol-forming substrate may have a cellulose-based reinforcement content greater than about 1 percent by weight. The aerosol-forming substrate may have a cellulose-based reinforcement content greater than about 5 percent by weight. The aerosol-forming substrate may have a cellulose-based reinforcement content greater than about 10 percent by weight. The aerosol-forming substrate may have a cellulose-based reinforcement content greater than about 15 percent by weight. The aerosol-forming substrate may have a cellulose-based reinforcement content greater than about 20 percent by weight.

The aerosol-forming substrate may have a cellulose-based reinforcement content of less than about 50 percent by weight. The aerosol-forming substrate may have a cellulose-based reinforcement content of less than about 45 percent by weight. The aerosol-forming substrate may have a cellulose-based reinforcement content of less than about 40 percent by weight. The aerosol-forming substrate may have a cellulose-based reinforcement content of less than about 35 percent by weight. The aerosol-forming substrate may have a cellulose-based reinforcement content of less than about 30 percent by weight. The aerosol-forming substrate may have a cellulose-based reinforcement content of less than about 25 percent by weight. The aerosol-forming substrate may have a cellulose-based reinforcement content of less than about 20 percent by weight. The aerosol-forming substrate may have a cellulose-based strengthening agent content of less than about 15 percent by weight.

The aerosol-forming substrate may have a cellulose-based reinforcement content of from about 0.5 percent by weight to about 50 percent by weight. The aerosol-forming substrate may have a cellulose-based reinforcement content of from about 0.5 percent by weight to about 45 percent by weight. The aerosol-forming substrate may have a cellulose-based reinforcement content of from about 0.5 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a cellulose-based reinforcement content of from about 0.5 percent by weight to about 35 percent by weight. The aerosol-forming substrate may have a cellulose-based reinforcement content of from about 0.5 percent by weight to about 30 percent by weight. The aerosol-forming substrate may have a cellulose-based reinforcement content of from about 0.5 percent by weight to about 25 percent by weight. The aerosol-forming substrate may have a cellulose-based reinforcement content of from about 0.5 percent by weight to about 20 percent by weight. The aerosol-forming substrate may have a cellulose-based reinforcement content of from about 0.5 percent by weight to about 15 percent by weight. The aerosol-forming substrate may have a cellulose-based reinforcement content of from about 0.5 percent by weight to about 10 percent by weight. The aerosol-forming substrate may have a cellulose-based reinforcement content of from about 0.5 percent by weight to about 5 percent by weight.

The aerosol-forming substrate may have a cellulose-based reinforcement content of from about 1 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a cellulose-based reinforcement content of from about 5 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a cellulose-based reinforcement content of from about 10 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a cellulose-based reinforcement content of from about 15 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a cellulose-based reinforcement content of from about 20 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a cellulose-based reinforcement content of about 25 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a cellulose-based reinforcement content of about 30 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a cellulose-based reinforcement content of about 35 percent by weight to about 40 percent by weight.

The aerosol-forming substrate may have a cellulose-based reinforcement content of from about 1 percent by weight to about 35 percent by weight. The aerosol-forming substrate may have a cellulose-based reinforcement content of from about 5 percent by weight to about 35 percent by weight. The aerosol-forming substrate may have a cellulose-based reinforcement content of from about 5 percent by weight to about 30 percent by weight. The aerosol-forming substrate may have a cellulose-based reinforcement content of from about 10 percent by weight to about 30 percent by weight. The aerosol-forming substrate may have a cellulose-based reinforcement content of from about 10 percent by weight to about 25 percent by weight. The aerosol-forming substrate may have a cellulose-based strengthening agent content of from about 15 percent by weight to about 25 percent by weight. The aerosol-forming substrate may have a cellulose-based strengthening agent content of from about 15 percent by weight to about 20 percent by weight.

One or more cellulose-based reinforcing agents may comprise cellulose fibers. Advantageously, the inventors have found that cellulose fibers may be a cellulose-based reinforcing agent that is particularly effective in increasing the tensile strength of an aerosol-forming substrate.

The aerosol-forming substrate may have a cellulose fiber content greater than about 0.5 percent by weight. The aerosol-forming substrate may have a cellulose fiber content greater than about 1 percent by weight. The aerosol-forming substrate may have a cellulose fiber content greater than about 5 percent by weight. The aerosol-forming substrate may have a cellulose fiber content greater than about 10 percent by weight. The aerosol-forming substrate may have a cellulose fiber content greater than about 15 percent by weight. The aerosol-forming substrate may have a cellulose fiber content greater than about 20 percent by weight.

The aerosol-forming substrate may have a cellulose fiber content of less than about 50 percent by weight. The aerosol-forming substrate may have a cellulose fiber content of less than about 45 percent by weight. The aerosol-forming substrate may have a cellulose fiber content of less than about 40 percent by weight. The aerosol-forming substrate may have a cellulose fiber content of less than about 35 percent by weight. The aerosol-forming substrate may have a cellulose fiber content of less than about 30 percent by weight. The aerosol-forming substrate may have a cellulose fiber content of less than about 25 percent by weight. The aerosol-forming substrate may have a cellulose fiber content of less than about 20 percent by weight. The aerosol-forming substrate may have a cellulose fiber content of less than about 15 percent by weight.

The aerosol-forming substrate may have a cellulose fiber content of from about 0.5 percent by weight to about 50 percent by weight. The aerosol-forming substrate may have a cellulose fiber content of from about 0.5 percent by weight to about 45 percent by weight. The aerosol-forming substrate may have a cellulose fiber content of from about 0.5 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a cellulose fiber content of from about 0.5 percent by weight to about 35 percent by weight. The aerosol-forming substrate may have a cellulose fiber content of from about 0.5 percent by weight to about 30 percent by weight. The aerosol-forming substrate may have a cellulose fiber content of from about 0.5 percent by weight to about 25 percent by weight. The aerosol-forming substrate may have a cellulose fiber content of about 0.5 percent by weight to about 20 percent by weight. The aerosol-forming substrate may have a cellulose fiber content of about 0.5 percent by weight to about 15 percent by weight. The aerosol-forming substrate may have a cellulose fiber content of about 0.5 percent by weight to about 10 percent by weight. The aerosol-forming substrate may have a cellulose fiber content of about 0.5 percent by weight to about 5 percent by weight.

The aerosol-forming substrate may have a cellulose fiber content of from about 1 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a cellulose fiber content of from about 5 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a cellulose fiber content of from about 10 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a cellulose fiber content of from about 15 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a cellulose fiber content of from about 20 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a cellulose fiber content of from about 25 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a cellulose fiber content of from about 30 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a cellulose fiber content of from about 35 percent by weight to about 40 percent by weight.

The aerosol-forming substrate may have a cellulose fiber content of from about 1 percent by weight to about 35 percent by weight. The aerosol-forming substrate may have a cellulose fiber content of from about 5 percent by weight to about 35 percent by weight. The aerosol-forming substrate may have a cellulose fiber content of from about 5 percent by weight to about 30 percent by weight. The aerosol-forming substrate may have a cellulose fiber content of from about 10 percent by weight to about 30 percent by weight. The aerosol-forming substrate may have a cellulose fiber content of from about 10 percent by weight to about 25 percent by weight. The aerosol-forming substrate may have a cellulose fiber content of from about 15 percent by weight to about 25 percent by weight. The aerosol-forming substrate may have a cellulose fiber content of from about 15 percent by weight to about 20 percent by weight.

One or more cellulose-based reinforcing agents may comprise microcrystalline cellulose. Advantageously, the inventors have found that microcrystalline cellulose may be a cellulose-based reinforcing agent that is particularly effective in increasing the tensile strength of an aerosol-forming substrate.

The aerosol-forming substrate may have a microcrystalline cellulose content greater than about 0.5 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content greater than about 1 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content greater than about 5 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content greater than about 10 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content greater than about 15 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content greater than about 20 percent by weight.

The aerosol-forming substrate may have a microcrystalline cellulose content of less than about 50 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content of less than about 45 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content of less than about 40 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content of less than about 35 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content of less than about 30 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content of less than about 25 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content of less than about 20 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content of less than about 15 percent by weight.

The aerosol-forming substrate may have a microcrystalline cellulose content of from about 0.5 percent by weight to about 50 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content of from about 0.5 percent by weight to about 45 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content of from about 0.5 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content of from about 0.5 percent by weight to about 35 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content of from about 0.5 percent by weight to about 30 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content of from about 0.5 percent by weight to about 25 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content of from about 0.5 percent by weight to about 20 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content of from about 0.5 percent by weight to about 15 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content of from about 0.5 percent by weight to about 10 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content of from about 0.5 percent by weight to about 5 percent by weight.

The aerosol-forming substrate may have a microcrystalline cellulose content of from about 1 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content of from about 5 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content of from about 10 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content of from about 15 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content of from about 20 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content of from about 25 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content of from about 30 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content of from about 35 percent by weight to about 40 percent by weight.

The aerosol-forming substrate may have a microcrystalline cellulose content of from about 1 percent by weight to about 35 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content of from about 5 percent by weight to about 35 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content of from about 5 percent by weight to about 30 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content of from about 10 percent by weight to about 30 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content of from about 10 percent by weight to about 25 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content of from about 15 percent by weight to about 25 percent by weight. The aerosol-forming substrate may have a microcrystalline cellulose content of from about 15 percent by weight to about 20 percent by weight.

One or more cellulose-based reinforcing agents may comprise cellulose powder. Advantageously, the inventors have found that cellulose powder may be a cellulose-based reinforcing agent that is particularly effective in increasing the tensile strength of the aerosol-forming substrate.

The aerosol-forming substrate may have a cellulose powder content of more than about 0.5 percent by weight. The aerosol-forming substrate may have a cellulose powder content of more than about 1 percent by weight. The aerosol-forming substrate may have a cellulose powder content of more than about 5 percent by weight. The aerosol-forming substrate may have a cellulose powder content of more than about 10 percent by weight. The aerosol-forming substrate may have a cellulose powder content of more than about 15 percent by weight. The aerosol-forming substrate may have a cellulose powder content of more than about 20 percent by weight.

The aerosol-forming substrate may have a cellulose powder content of less than about 50 percent by weight. The aerosol-forming substrate may have a cellulose powder content of less than about 45 percent by weight. The aerosol-forming substrate may have a cellulose powder content of less than about 40 percent by weight. The aerosol-forming substrate may have a cellulose powder content of less than about 35 percent by weight. The aerosol-forming substrate may have a cellulose powder content of less than about 30 percent by weight. The aerosol-forming substrate may have a cellulose powder content of less than about 25 percent by weight. The aerosol-forming substrate may have a cellulose powder content of less than about 20 percent by weight. The aerosol-forming substrate may have a cellulose powder content of less than about 15 percent by weight.

The aerosol-forming substrate may have a cellulose powder content of about 0.5 percent by weight to about 50 percent by weight. The aerosol-forming substrate may have a cellulose powder content of about 0.5 percent by weight to about 45 percent by weight. The aerosol-forming substrate may have a cellulose powder content of about 0.5 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a cellulose powder content of about 0.5 percent by weight to about 35 percent by weight. The aerosol-forming substrate may have a cellulose powder content of about 0.5 percent by weight to about 30 percent by weight. The aerosol-forming substrate may have a cellulose powder content of about 0.5 percent by weight to about 25 percent by weight. The aerosol-forming substrate may have a cellulose powder content of about 0.5 percent by weight to about 20 percent by weight. The aerosol-forming substrate may have a cellulose powder content of about 0.5 percent by weight to about 15 percent by weight. The aerosol-forming substrate may have a cellulose powder content of about 0.5 percent by weight to about 10 percent by weight. The aerosol-forming substrate may have a cellulose powder content of about 0.5 percent by weight to about 5 percent by weight.

The aerosol-forming substrate may have a cellulose powder content of about 1 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a cellulose powder content of about 5 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a cellulose powder content of about 10 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a cellulose powder content of about 15 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a cellulose powder content of about 20 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a cellulose powder content of about 25 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a cellulose powder content of from about 30 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have a cellulose powder content of from about 35 percent by weight to about 40 percent by weight.

The aerosol-forming substrate may have a cellulose powder content of from about 1 percent by weight to about 35 percent by weight. The aerosol-forming substrate may have a cellulose powder content of from about 5 percent by weight to about 35 percent by weight. The aerosol-forming substrate may have a cellulose powder content of from about 5 percent by weight to about 30 percent by weight. The aerosol-forming substrate may have a cellulose powder content of from about 10 percent by weight to about 30 percent by weight. The aerosol-forming substrate may have a cellulose powder content of from about 10 percent by weight to about 25 percent by weight. The aerosol-forming substrate may have a cellulose powder content of from about 15 percent by weight to about 25 percent by weight. The aerosol-forming substrate may have a cellulose powder content of from about 15 percent by weight to about 20 percent by weight.

The aerosol-forming substrate may comprise carboxymethylcellulose. Advantageously, the use of carboxymethylcellulose may help reduce crust formation on the aerosol-forming substrate when used in an aerosol-generating article. In some examples, the use of carboxymethylcellulose eliminates crust formation. As explained below, crust formation is the formation of a solid layer on a component of the aerosol-generating article. The inventors of the present invention have found that crust formation may occur because a component of the aerosol-forming substrate may melt and then re-solidify around a component of the aerosol-generating article. Crust formation may be a particular problem when the aerosol-forming substrate is used in an aerosol-generating article comprising a susceptor. If a crust forms on the current collector, the crusted current collector becomes less effective at heating the aerosol-forming substrate, which may result in decreased nicotine delivery to the user and/or decreased aerosol formation from the aerosol-forming substrate.

The carboxymethyl cellulose may comprise sodium carboxymethyl cellulose. Advantageously, the inventors of the present invention have found that sodium carboxymethyl cellulose is a carboxymethyl cellulose that can be particularly effective in preventing the above-mentioned problem associated with crust formation.

The aerosol-forming substrate may have a carboxymethylcellulose content greater than about 0.5 percent by weight. The aerosol-forming substrate may have a carboxymethylcellulose content greater than about 1 percent by weight. The aerosol-forming substrate may have a carboxymethylcellulose content greater than about 5 percent by weight. The aerosol-forming substrate may have a carboxymethylcellulose content greater than about 10 percent by weight.

The aerosol-forming substrate may have a carboxymethylcellulose content of less than about 20 percent by weight. The aerosol-forming substrate may have a carboxymethylcellulose content of less than about 15 percent by weight. The aerosol-forming substrate may have a carboxymethylcellulose content of less than about 10 percent by weight. The aerosol-forming substrate may have a carboxymethylcellulose content of less than about 8 percent by weight. The aerosol-forming substrate may have a carboxymethylcellulose content of less than about 5 percent by weight.

The aerosol-forming substrate may have a carboxymethylcellulose content of from about 0.5 percent by weight to about 20 percent by weight. The aerosol-forming substrate may have a carboxymethylcellulose content of from about 0.5 percent by weight to about 15 percent by weight. The aerosol-forming substrate may have a carboxymethylcellulose content of from about 0.5 percent by weight to about 10 percent by weight. The aerosol-forming substrate may have a carboxymethylcellulose content of from about 0.5 percent by weight to about 8 percent by weight. The aerosol-forming substrate may have a carboxymethylcellulose content of from about 0.5 percent by weight to about 5 percent by weight.

The aerosol-forming substrate may have a carboxymethylcellulose content of from about 1 percent by weight to about 20 percent by weight. The aerosol-forming substrate may have a carboxymethylcellulose content of from about 5 percent by weight to about 20 percent by weight. The aerosol-forming substrate may have a carboxymethylcellulose content of from about 8 percent by weight to about 20 percent by weight. The aerosol-forming substrate may have a carboxymethylcellulose content of from about 10 percent by weight to about 20 percent by weight. The aerosol-forming substrate may have a carboxymethylcellulose content of from about 15 percent by weight to about 20 percent by weight.

The aerosol-forming substrate may have a carboxymethylcellulose content of about 1 percent by weight to about 15 percent by weight. The aerosol-forming substrate may have a carboxymethylcellulose content of about 1 percent by weight to about 10 percent by weight. The aerosol-forming substrate may have a carboxymethylcellulose content of about 5 percent by weight to about 10 percent by weight. The aerosol-forming substrate may have a carboxymethylcellulose content of about 5 percent by weight to about 8 percent by weight.

The aerosol-forming substrate may contain nicotine.

The nicotine may comprise one or more nicotine salts. The one or more nicotine salts may be selected from the list consisting of nicotine lactate, nicotine citrate, nicotine pyruvate, nicotine bitartrate, nicotine benzoate, nicotine pectate, nicotine alginate, and nicotine salicylate.

Nicotine may contain tobacco extract.

The aerosol-forming substrate may have a nicotine content of greater than about 0.5 percent by weight. The aerosol-forming substrate may have a nicotine content of greater than about 1 percent by weight. The aerosol-forming substrate may have a nicotine content of greater than about 2 percent by weight. The aerosol-forming substrate may have a nicotine content of greater than about 3 percent by weight. The aerosol-forming substrate may have a nicotine content of greater than about 5 percent by weight. The aerosol-forming substrate may have a nicotine content of greater than about 8 percent by weight.

The aerosol-forming substrate may have a nicotine content of less than about 10 percent by weight. The aerosol-forming substrate may have a nicotine content of less than about 8 percent by weight. The aerosol-forming substrate may have a nicotine content of less than about 5 percent by weight. The aerosol-forming substrate may have a nicotine content of less than about 3 percent by weight. The aerosol-forming substrate may have a nicotine content of less than about 2 percent by weight. The aerosol-forming substrate may have a nicotine content of less than about 1 percent by weight.

The aerosol-forming substrate may have a nicotine content of about 0.5 percent by weight to about 10 percent by weight. The aerosol-forming substrate may have a nicotine content of about 0.5 percent by weight to about 8 percent by weight. The aerosol-forming substrate may have a nicotine content of about 0.5 percent by weight to about 5 percent by weight. The aerosol-forming substrate may have a nicotine content of about 0.5 percent by weight to about 3 percent by weight. The aerosol-forming substrate may have a nicotine content of about 0.5 percent by weight to about 2 percent by weight. The aerosol-forming substrate may have a nicotine content of about 0.5 percent by weight to about 1 percent by weight.

The aerosol-forming substrate may have a nicotine content of about 1 percent by weight to about 5 percent by weight. The aerosol-forming substrate may have a nicotine content of about 2 percent by weight to about 5 percent by weight. The aerosol-forming substrate may have a nicotine content of about 3 percent by weight to about 5 percent by weight.

The aerosol-forming substrate may have a nicotine content of about 0.5 percent by weight to about 4 percent by weight. The aerosol-forming substrate may have a nicotine content of about 1 percent by weight to about 4 percent by weight. The aerosol-forming substrate may have a nicotine content of about 1 percent by weight to about 3 percent by weight. The aerosol-forming substrate may have a nicotine content of about 1 percent by weight to about 2 percent by weight.

The aerosol-forming substrate may contain one or more carboxylic acids. Advantageously, the inclusion of one or more carboxylic acids in the aerosol-forming substrate may create a nicotine salt.

The one or more carboxylic acids comprise one or more of lactic acid and levulinic acid. Advantageously, the present inventors have found that lactic acid and levulinic acid are particularly suitable carboxylic acids for creating nicotine salts.

The aerosol-forming substrate may have a carboxylic acid content greater than about 0.5 percent by weight. The aerosol-forming substrate may have a carboxylic acid content greater than about 1 percent by weight. The aerosol-forming substrate may have a carboxylic acid content greater than about 2 percent by weight. The aerosol-forming substrate may have a carboxylic acid content greater than about 3 percent by weight. The aerosol-forming substrate may have a carboxylic acid content greater than about 5 percent by weight. The aerosol-forming substrate may have a carboxylic acid content greater than about 8 percent by weight. The aerosol-forming substrate may have a carboxylic acid content greater than about 10 percent by weight. The aerosol-forming substrate may have a carboxylic acid content greater than about 15 percent by weight.

The aerosol-forming substrate may have a carboxylic acid content of less than about 20 percent by weight. The aerosol-forming substrate may have a carboxylic acid content of less than about 15 percent by weight. The aerosol-forming substrate may have a carboxylic acid content of less than about 10 percent by weight. The aerosol-forming substrate may have a carboxylic acid content of less than about 8 percent by weight. The aerosol-forming substrate may have a carboxylic acid content of less than about 5 percent by weight. The aerosol-forming substrate may have a carboxylic acid content of less than about 3 percent by weight. The aerosol-forming substrate may have a carboxylic acid content of less than about 2 percent by weight. The aerosol-forming substrate may have a carboxylic acid content of less than about 1 percent by weight.

The aerosol-forming substrate may have a carboxylic acid content of about 0.5 percent by weight to about 20 percent by weight. The aerosol-forming substrate may have a carboxylic acid content of about 0.5 percent by weight to about 15 percent by weight. The aerosol-forming substrate may have a carboxylic acid content of about 0.5 percent by weight to about 10 percent by weight. The aerosol-forming substrate may have a carboxylic acid content of about 0.5 percent by weight to about 8 percent by weight. The aerosol-forming substrate may have a carboxylic acid content of about 0.5 percent by weight to about 5 percent by weight. The aerosol-forming substrate may have a carboxylic acid content of about 0.5 percent by weight to about 3 percent by weight. The aerosol-forming substrate may have a carboxylic acid content of from about 0.5 percent by weight to about 2 percent by weight. The aerosol-forming substrate may have a carboxylic acid content of from about 0.5 percent by weight to about 1 percent by weight.

The aerosol-forming substrate may have a carboxylic acid content of about 1 percent by weight to about 10 percent by weight. The aerosol-forming substrate may have a carboxylic acid content of about 2 percent by weight to about 10 percent by weight. The aerosol-forming substrate may have a carboxylic acid content of about 3 percent by weight to about 10 percent by weight. The aerosol-forming substrate may have a carboxylic acid content of about 5 percent by weight to about 10 percent by weight. The aerosol-forming substrate may have a carboxylic acid content of about 8 percent by weight to about 10 percent by weight.

The aerosol-forming substrate may have a carboxylic acid content of about 1 percent by weight to about 20 percent by weight. The aerosol-forming substrate may have a carboxylic acid content of about 1 percent by weight to about 15 percent by weight. The aerosol-forming substrate may have a carboxylic acid content of about 1 percent by weight to about 10 percent by weight. The aerosol-forming substrate may have a carboxylic acid content of about 1 percent by weight to about 8 percent by weight. The aerosol-forming substrate may have a carboxylic acid content of about 2 percent by weight to about 5 percent by weight. The aerosol-forming substrate may have a carboxylic acid content of about 3 percent by weight to about 5 percent by weight.

The aerosol-forming substrate may include one or more aerosol-forming substances. Advantageously, the inclusion of one or more aerosol-forming substances in the aerosol-forming substrate improves aerosol formation.

One or more aerosol forming agents may comprise glycerin. One or more aerosol forming agents may comprise propylene glycol. One or more aerosol forming agents may comprise a combination of glycerin and propylene glycol.

The aerosol-forming substrate may have an aerosol-forming substance content of more than about 0.5 percent by weight. The aerosol-forming substrate may have an aerosol-forming substance content of more than about 10 percent by weight. The aerosol-forming substrate may have an aerosol-forming substance content of more than about 20 percent by weight. The aerosol-forming substrate may have an aerosol-forming substance content of more than about 30 percent by weight. The aerosol-forming substrate may have an aerosol-forming substance content of more than about 40 percent by weight. The aerosol-forming substrate may have an aerosol-forming substance content of more than about 50 percent by weight. The aerosol-forming substrate may have an aerosol-forming substance content of more than about 60 percent by weight.

The aerosol-forming substrate may have an aerosol-forming substance content of less than about 80 percent by weight. The aerosol-forming substrate may have an aerosol-forming substance content of less than about 70 percent by weight. The aerosol-forming substrate may have an aerosol-forming substance content of less than about 60 percent by weight.

The aerosol-forming substrate may have an aerosol-forming substance content of from about 0.5 percent by weight to about 80 percent by weight. The aerosol-forming substrate may have an aerosol-forming substance content of from about 0.5 percent by weight to about 70 percent by weight. The aerosol-forming substrate may have an aerosol-forming substance content of from about 0.5 percent by weight to about 60 percent by weight. The aerosol-forming substrate may have an aerosol-forming substance content of from about 0.5 percent by weight to about 50 percent by weight. The aerosol-forming substrate may have an aerosol-forming substance content of from about 0.5 percent by weight to about 40 percent by weight. The aerosol-forming substrate may have an aerosol-forming substance content of from about 0.5 percent by weight to about 30 percent by weight. The aerosol-forming substrate may have an aerosol-forming substance content of from about 0.5 percent by weight to about 20 percent by weight. The aerosol-forming substrate may have an aerosol-forming substance content of from about 0.5 percent by weight to about 10 percent by weight.

The aerosol-forming substrate may have an aerosol-forming substance content of from about 1 percent by weight to about 80 percent by weight. The aerosol-forming substrate may have an aerosol-forming substance content of from about 10 percent by weight to about 80 percent by weight. The aerosol-forming substrate may have an aerosol-forming substance content of from about 20 percent by weight to about 80 percent by weight. The aerosol-forming substrate may have an aerosol-forming substance content of from about 30 percent by weight to about 80 percent by weight. The aerosol-forming substrate may have an aerosol-forming substance content of from about 40 percent by weight to about 80 percent by weight. The aerosol-forming substrate may have an aerosol-forming substance content of from about 50 percent by weight to about 80 percent by weight. The aerosol-forming substrate may have an aerosol-forming substance content of from about 60 percent by weight to about 80 percent by weight. The aerosol-forming substrate may have an aerosol-forming substance content of from about 70 percent by weight to about 80 percent by weight.

The aerosol-forming substrate may have an aerosol-forming substance content of from about 20 percent by weight to about 80 percent by weight. The aerosol-forming substrate may have an aerosol-forming substance content of from about 30 percent by weight to about 80 percent by weight. The aerosol-forming substrate may have an aerosol-forming substance content of from about 30 percent by weight to about 70 percent by weight. The aerosol-forming substrate may have an aerosol-forming substance content of from about 40 percent by weight to about 70 percent by weight. The aerosol-forming substrate may have an aerosol-forming substance content of from about 40 percent by weight to about 60 percent by weight. The aerosol-forming substrate may have an aerosol-forming substance content of from about 50 percent by weight to about 60 percent by weight.

The ratio of the weight percent content of hydroxypropyl methylcellulose to the weight percent content of the cellulose-based strengthening agent in the aerosol-forming substrate may be greater than or equal to about 1. The ratio of the weight percent content of hydroxypropyl methylcellulose to the weight percent content of the cellulose-based strengthening agent in the aerosol-forming substrate may be greater than or equal to about 1.25. The ratio of the weight percent content of hydroxypropyl methylcellulose to the weight percent content of the cellulose-based strengthening agent in the aerosol-forming substrate may be greater than or equal to about 1.5.

The ratio of the weight percent content of hydroxypropyl methylcellulose to the weight percent content of the cellulose-based strengthening agent in the aerosol-forming substrate may be less than or equal to about 1. The ratio of the weight percent content of hydroxypropyl methylcellulose to the weight percent content of the cellulose-based strengthening agent in the aerosol-forming substrate may be less than or equal to about 0.75. The ratio of the weight percent content of hydroxypropyl methylcellulose to the weight percent content of the cellulose-based strengthening agent in the aerosol-forming substrate may be less than or equal to about 0.5.

An aerosol generating article may include an aerosol generating substrate.

The aerosol generating article may contain a hollow cellulose acetate tube.

The aerosol generating article may contain a separating element.

An aerosol generating product may contain a mouthpiece filter.

The aerosol-forming substrate, the hollow cellulose acetate tube, the separating element, and the mouthpiece filter may be arranged in series. The aerosol-forming substrate, the hollow cellulose acetate tube, the separating element, and the mouthpiece filter may be arranged in coaxial alignment.

The aerosol generating product may contain cigarette paper.

The aerosol-forming substrate, the hollow cellulose acetate tube, the separating element and the mouthpiece filter can be assembled together with cigarette paper.

The aerosol generating article may have a mouthpiece end and a distal end 1013. When used, the user may insert the mouthpiece end into his or her mouth.

The aerosol generating article may be suitable for use with an electrically controlled aerosol generating device comprising a heater for heating an aerosol generating substrate.

The aerosol forming substrate can be provided in the form of a plug.

An aerosol generating product may contain a current collector.

The current collector may be a plurality of current-receiving particles that may be deposited on the aerosol-forming substrate or embedded in it. The current-receiving particles may be immobilized by the aerosol-forming substrate and remain in their original position. The current-receiving particles may be uniformly distributed in the aerosol-forming substrate. Due to the fact that the receiver has the form of particles, heat may be produced according to the distribution of particles in the aerosol-forming substrate. Alternatively, the current collector may be in the form of one or more sheets, strips, pieces or rods that may be placed near the aerosol-forming substrate or embedded in it. The aerosol-forming substrate may comprise one or more current-receiving strips.

The aerosol generating device may comprise a housing that forms a cavity of the device, configured to receive at least a portion of the aerosol generating article.

The aerosol generating device may comprise a nebulizer configured to generate an aerosol from an aerosol-forming substrate.

The atomizer may be a thermal atomizer.

As used herein, the term "thermal atomizer" describes an atomizer configured to heat an aerosol-forming substrate to generate an aerosol.

The aerosol generating device may comprise a thermal atomizer of any suitable type. For example, the thermal atomizer may comprise a heater. The thermal atomizer may comprise an electric heater. In one example, the thermal atomizer may comprise an electric heater comprising a heating element. The heating element may be a resistive heating element. In one example, the heating element may comprise a heating plate or pin adapted to be inserted into the aerosol-forming substrate so that the aerosol-forming substrate is heated from the inside. In another example, the heating element may partially or completely surround the aerosol-forming substrate and heat the aerosol-forming substrate circumferentially from the outside.

In another example, the thermal sprayer may comprise an induction heating device. Induction heating devices typically comprise an induction source configured to be connected to a current collector, which may be provided externally relative to the aerosol-forming substrate or internally in the aerosol-forming substrate. The induction source generates an alternating electromagnetic field that induces magnetization or eddy currents in the current collector. The current collector may be heated as a result of hysteresis losses or induced eddy currents that heat the current collector by means of ohmic or resistive heating.

The aerosol generating device may comprise a current collector. The current collector may be as described above in relation to the aerosol generating article.

An aerosol generating device comprising an induction heating device may be configured to receive an aerosol generating article having an aerosol forming substrate and a current collector located in thermal proximity to the aerosol forming substrate. Typically, the current collector is in direct contact with the aerosol forming substrate, and heat is transferred from the current collector to the aerosol forming substrate mainly by conduction.

Examples of electrically controlled aerosol generating systems comprising induction heating devices and aerosol generating articles comprising current collectors are described in documents WO-A1-95/27411 and WO-A1-2015/177255.

The aerosol generating device may contain a battery and control electronics.

Furthermore, an aerosol generating system is provided, comprising an aerosol-forming substrate according to the present invention and a nebulizer configured to generate an aerosol from the aerosol-forming substrate.

The atomizer may be a thermal atomizer.

The aerosol generating system may comprise a thermal atomizer of any suitable type. For example, the thermal atomizer may comprise a heater. The thermal atomizer may comprise an electric heater. In one example, the thermal atomizer may comprise an electric heater comprising a heating element. The heating element may be a resistive heating element. In one example, the heating element may comprise a heating plate or pin adapted to be inserted into the aerosol-forming substrate so that the aerosol-forming substrate is heated from the inside. In another example, the heating element may partially or completely surround the aerosol-forming substrate and heat the aerosol-forming substrate circumferentially from the outside.

In another example, the thermal sprayer may comprise an induction heating device. Induction heating devices typically comprise an induction source configured to be connected to a current collector, which may be provided externally relative to the aerosol-forming substrate or internally in the aerosol-forming substrate. The induction source generates an alternating electromagnetic field that induces magnetization or eddy currents in the current collector. The current collector may be heated as a result of hysteresis losses or induced eddy currents that heat the current collector by means of ohmic or resistive heating.

The aerosol generating system may comprise a current collector. The current collector may be as described above with respect to the aerosol generating article.

An aerosol generating system comprising an induction heating device may be configured to receive an aerosol generating article having an aerosol forming substrate and a current collector located in thermal proximity to the aerosol forming substrate. Typically, the current collector is in direct contact with the aerosol forming substrate and heat is transferred from the current collector to the aerosol forming substrate primarily by conduction.

Examples of electrically controlled aerosol generating systems comprising induction heating devices and aerosol generating articles comprising current collectors are described in documents WO-A1-95/27411 and WO-A1-2015/177255.

The aerosol generating system may contain a battery and control electronics.

For the avoidance of doubt, the features described above with respect to an aerosol-generating substrate may also apply, where applicable, to an aerosol-generating article, an aerosol-generating device, and an aerosol-generating system. Similarly, the features described above with respect to an aerosol-generating article may also apply, where applicable, to an aerosol-generating device and an aerosol-generating system, and vice versa.

It will be understood that any features described herein with respect to one embodiment of an aerosol-forming substrate, an aerosol-generating article, an aerosol-generating device, or an aerosol-generating system may also be applicable to other embodiments of aerosol-forming substrates, aerosol-generating articles, aerosol-generating devices, or aerosol-generating systems according to the present invention. A feature described with respect to one embodiment may be equally applicable to another embodiment according to this invention. It will also be understood that the aerosol generator according to the present invention may be provided in an aerosol-generating device without a cartridge. Accordingly, any of the features described herein with respect to a cartridge may be equally applicable to an aerosol-generating device.

The present invention is defined in the claims. However, a non-exhaustive list of non-limiting examples is provided below. Any one or more of the features of these examples may be combined with any one or more features of another example, embodiment or aspect described herein.

EX1. An aerosol-forming substrate for use in an aerosol-generating system, the aerosol-forming substrate comprising:

one or more substances for forming an aerosol;

hydroxypropyl methylcellulose; and

one or more cellulose-based reinforcing agents.

EX2. An aerosol-forming substrate according to example EX1, wherein the aerosol-forming substrate has a hydroxypropyl methylcellulose content of greater than about 0.5 percent by weight.

EX3. An aerosol-forming substrate according to example EX2, wherein the aerosol-forming substrate has a hydroxypropyl methylcellulose content of from about 0.5 percent by weight to about 50 percent by weight.

EX4. An aerosol-forming substrate according to example EX3, wherein the aerosol-forming substrate has a hydroxypropyl methylcellulose content of from about 10 percent by weight to about 40 percent by weight.

EX5. An aerosol-forming substrate according to example EX4, wherein the aerosol-forming substrate has a hydroxypropyl methylcellulose content of from about 15 percent by weight to about 30 percent by weight.

EX6. An aerosol-forming substrate according to example EX5, wherein the aerosol-forming substrate has a hydroxypropyl methylcellulose content of from about 20 percent by weight to about 25 percent by weight.

EX7. An aerosol-forming substrate according to any of examples EX1 to EX6, wherein the aerosol-forming substrate has a cellulose-based strengthening agent content of greater than about 0.5 percent by weight.

EX8. An aerosol-forming substrate according to example EX7, wherein the aerosol-forming substrate has a cellulose-based strengthening agent content of from about 0.5 percent by weight to about 50 percent by weight.

EX9. An aerosol-forming substrate according to example EX8, wherein the aerosol-forming substrate has a cellulose-based strengthening agent content of from about 0.5 percent by weight to about 40 percent by weight.

EX10. An aerosol-forming substrate according to example EX9, wherein the aerosol-forming substrate has a cellulose-based strengthening agent content of from about 5 percent by weight to about 30 percent by weight.

EX11. An aerosol-forming substrate according to example EX10, wherein the aerosol-forming substrate has a cellulose-based reinforcing agent content of from about 10 percent by weight to about 20 percent by weight.

EX12. An aerosol-forming substrate according to example EX11, wherein the aerosol-forming substrate has a cellulose-based strengthening agent content of from about 15 percent by weight to about 20 percent by weight.

EX13. An aerosol-forming substrate according to one of the examples EX1-EX12, wherein one or more cellulose-based reinforcing agents comprise cellulose fibres.

EX14. An aerosol-forming substrate according to example EX13, wherein the aerosol-forming substrate has a cellulose fibre content of greater than about 0.5 percent by weight.

EX15. An aerosol-forming substrate according to example EX14, wherein the aerosol-forming substrate has a cellulose fiber content of from about 0.5 percent by weight to about 50 percent by weight.

EX16. An aerosol-forming substrate according to example EX15, wherein the aerosol-forming substrate has a cellulose fiber content of from about 0.5 percent by weight to about 40 percent by weight.

EX17. An aerosol-forming substrate according to example EX16, wherein the aerosol-forming substrate has a cellulose fibre content of from about 5 percent by weight to about 30 percent by weight.

EX18. An aerosol-forming substrate according to example EX17, wherein the aerosol-forming substrate has a cellulose fibre content of from about 10 percent by weight to about 20 percent by weight.

EX19. An aerosol-forming substrate according to example EX18, wherein the aerosol-forming substrate has a cellulose fibre content of from about 15 percent by weight to about 20 percent by weight.

EX20. An aerosol-forming substrate according to one of the examples EX1-EX19, wherein one or more cellulose-based reinforcing agents comprise microcrystalline cellulose.

EX21. An aerosol-forming substrate according to example EX20, wherein the aerosol-forming substrate has a microcrystalline cellulose content of greater than about 0.5 percent by weight.

EX22. An aerosol-forming substrate according to example EX21, wherein the aerosol-forming substrate has a microcrystalline cellulose content of from about 0.5 percent by weight to about 50 percent by weight.

EX23. An aerosol-forming substrate according to example EX22, wherein the aerosol-forming substrate has a microcrystalline cellulose content of from about 0.5 percent by weight to about 40 percent by weight.

EX24. An aerosol-forming substrate according to example EX23, wherein the aerosol-forming substrate has a microcrystalline cellulose content of from about 5 percent by weight to about 30 percent by weight.

EX25. An aerosol-forming substrate according to example EX18, wherein the aerosol-forming substrate has a microcrystalline cellulose content of from about 10 percent by weight to about 20 percent by weight.

EX26. An aerosol-forming substrate according to example EX24, wherein the aerosol-forming substrate has a microcrystalline cellulose content of from about 15 percent by weight to about 20 percent by weight.

EX27. An aerosol-forming substrate according to any of the examples EX1 to EX26, wherein the one or more cellulose-based reinforcing agents comprise cellulose powder.

EX28. An aerosol-forming substrate according to example EX27, wherein the aerosol-forming substrate has a cellulose powder content of more than about 0.5 percent by weight.

EX29. An aerosol-forming substrate according to example EX28, wherein the aerosol-forming substrate has a cellulose powder content of from about 0.5 percent by weight to about 50 percent by weight.

EX30. An aerosol-forming substrate according to example EX29, wherein the aerosol-forming substrate has a cellulose powder content of from about 0.5 percent by weight to about 40 percent by weight.

EX31. An aerosol-forming substrate according to example EX30, wherein the aerosol-forming substrate has a cellulose powder content of from about 5 percent by weight to about 30 percent by weight.

EX32. An aerosol-forming substrate according to example EX31, wherein the aerosol-forming substrate has a cellulose powder content of from about 10 percent by weight to about 20 percent by weight.

EX33. An aerosol-forming substrate according to example EX32, wherein the aerosol-forming substrate has a cellulose powder content of from about 15 percent by weight to about 20 percent by weight.

EX34. An aerosol-forming substrate according to any of examples EX1 to EX33, wherein the aerosol-forming substrate comprises carboxymethylcellulose.

EX35. An aerosol-forming substrate according to example EX34, wherein the aerosol-forming substrate has a carboxymethylcellulose content of greater than about 0.5 percent by weight.

EX36. An aerosol-forming substrate according to example EX35, wherein the aerosol-forming substrate has a carboxymethylcellulose content of from about 0.5 percent by weight to about 20 percent by weight.

EX37. An aerosol-forming substrate according to example EX36, wherein the aerosol-forming substrate has a carboxymethylcellulose content of from about 0.5 percent by weight to about 15 percent by weight.

EX38. An aerosol-forming substrate according to example EX37, wherein the aerosol-forming substrate has a carboxymethylcellulose content of from about 5 percent by weight to about 10 percent by weight.

EX39. An aerosol-forming substrate according to example EX38, wherein the aerosol-forming substrate has a carboxymethylcellulose content of from about 5 percent by weight to about 7 percent by weight.

EX40. An aerosol-forming substrate according to any of examples EX28 to EX39, wherein the carboxymethylcellulose comprises sodium carboxymethylcellulose.

EX41. An aerosol-forming substrate according to any of examples EX1-EX40, wherein the aerosol-forming substrate comprises nicotine.

EX42. An aerosol-forming substrate according to example EX41, wherein the aerosol-forming substrate has a nicotine content of greater than about 0.5 percent by weight.

EX43. An aerosol-forming substrate according to example EX42, wherein the aerosol-forming substrate has a nicotine content of from about 0.5 percent by weight to about 5 percent by weight.

EX44. An aerosol-forming substrate according to any of examples EX1 to EX43, wherein the aerosol-forming substrate comprises one or more carboxylic acids.

EX45. An aerosol-forming substrate according to example EX44, wherein the one or more carboxylic acids comprise one or more of lactic acid and levulinic acid.

EX46. An aerosol-generating article comprising an aerosol-forming substrate according to any of examples EX1 to EX45.

EX42. An aerosol generating system comprising:

an aerosol generating device; and

an aerosol generating article comprising, according to example EX46.

Specific embodiments will now be described by way of example only with reference to the accompanying drawings, in which:

Fig. 1 shows an example of an aerosol generating article comprising an aerosol forming substrate as described herein; and

Fig. 2 shows an example of an aerosol generating system comprising an aerosol generating device and an aerosol generating article shown in Fig. 1.

Aerosol generating systems for delivering an aerosol to a user typically include an atomizer configured to generate an inhalable aerosol from an aerosol-forming substrate. Some known aerosol generating systems include a thermal atomizer, such as an electric heater or an induction heating device. The thermal atomizer is designed to heat and vaporize an aerosol-forming substrate to generate an aerosol. Common aerosol-forming substrates for use in aerosol generating systems are nicotine-based formulations, which may be liquid nicotine-based formulations containing an aerosol-forming substance, such as glycerin and/or propylene glycol.

Some aerosol-generating substrates have low tensile strength. This means that such aerosol-generating substrates may break down or deteriorate before the aerosol-generating product is used by the user, which is undesirable. Some aerosol-generating substrates are prone to melting, which may result in crust formation on a portion of the aerosol-generating product. A crust formation on a portion of the aerosol-generating product may reduce the level of nicotine delivered to the user. A crust formation on a portion of the aerosol-generating product may reduce the volume of aerosol generated by the aerosol-generating system.

For example, as discussed above, in an aerosol generating system that includes an induction heating device, the aerosol generating article may include a susceptor that can be heated by an induction source. Heat from the susceptor is then transferred to an aerosol-forming substrate. Components of the aerosol-forming substrate may then evaporate to form an aerosol. However, if the susceptor is coated with a crust of the aerosol-forming substrate, the crust may reduce the transfer of heat from the heated susceptor to the aerosol-forming substrate. Reducing the heat transfer from the heated susceptor to the aerosol-forming substrate may reduce the level of nicotine delivered to the user. Reducing the heat transfer from the heated susceptor to the aerosol-forming substrate may reduce the amount of aerosol generated by the aerosol generating system.

Therefore, it is desirable to provide an aerosol-forming substrate that has an increased tensile strength. It is also desirable to provide an aerosol-forming substrate that has a reduced melting tendency, which can reduce the effect of crusting of the aerosol-forming substrate on the aerosol-generating article component.

Fig. 1 shows an example of an aerosol generating article 1000 comprising an aerosol forming substrate as described herein.

In the example of Fig. 1, the aerosol generating article 1000 comprises four elements: an aerosol forming substrate 1020, a hollow cellulose acetate tube 1030, a separator element 1040 and a mouthpiece filter 1050. The four elements 1020, 1030, 1040, 1050 are arranged in series and in coaxial alignment. The four elements 1020, 1030, 1040, 1050 are assembled together by a cigarette paper 1060 to form the aerosol generating article 1000.

In the example shown in Fig. 1, the aerosol generating article 1000 has a mouth end 1012 and a distal end 1013. In use, the user can insert the mouth end 1012 into his mouth. The distal end 1013 is located at the end of the aerosol generating article 1000 opposite the mouth end 1012. The example of the aerosol generating article 1000 shown in Fig. 1 is particularly suitable for use with an electrically controlled aerosol generating device comprising a heater for heating an aerosol generating substrate.

In one example, when assembled, the length of the aerosol generating article 1000 is approximately 45 millimeters, the outer diameter is approximately 7.2 millimeters, and the inner diameter is approximately 6.9 millimeters.

In the example shown in Fig. 1, the aerosol-forming substrate 1020 is in the form of a plug made by corrugating a sheet of aerosol-forming substrate. A number of examples of aerosol-forming substrate 1020 are shown below in Table 1. The sheet is assembled, corrugated, and wrapped with filter paper (not shown) to form a plug.

The aerosol generating article 1000 shown in Fig. 1 is designed to be coupled with an aerosol generating device for consumption. Such an aerosol generating device comprises means for heating an aerosol generating substrate 1020 to a temperature sufficient to form an aerosol. Typically, the aerosol generating device may comprise a heating element that surrounds the aerosol generating article 1000 near the aerosol generating substrate 1020, or a heating element that is inserted into the aerosol generating substrate 1020.

After the article is engaged with the aerosol generating device, the user takes a puff on the mouth end 1012 of the smoking article 1000 and the aerosol forming substrate 1020 is heated to a temperature of approximately 375 degrees Celsius. At this temperature, volatile compounds are released from the aerosol forming substrate 1020. These compounds condense to form an aerosol. The aerosol is drawn through the filter 1050 and into the user's mouth.

Fig. 2 shows a portion of an electrically controlled aerosol generating system 2000. The aerosol generating system uses a heating plate 2100 to heat an aerosol generating substrate 1020 of an aerosol generating article 1000. In the example shown in Fig. 2, the heating plate 2100 is mounted inside a chamber receiving an aerosol article of an electrically controlled aerosol generating device 2010. A plurality of air holes 2050 are formed in the aerosol generating device 2010 to provide air passage to the aerosol generating article 1000. The air flow is indicated by arrows in Fig. 2. The aerosol generating device 2010 comprises a power supply unit and an electronic circuit, which are not shown in Fig. 2. The aerosol generating article 1000 shown in Fig. 2, similar to that described in relation to Fig. 1.

Examples

Examples of aerosol-forming substrate compositions according to the present invention (Examples A, B, C, D and E) are prepared with the compositions shown in Table 1.

The aerosol forming substrates shown in Examples A, B, C, D and E are prepared by:

(1) mixing the components with water using heat and stirring to form a suspension;

(2) applying a layer of the suspension onto a flat surface to form a film approximately 210 micrometers thick;

(3) leaving the film on a flat surface to harden; and

(3) drying the film by heating the film to approximately 140°C for approximately 8 minutes.

The resulting aerosol-forming substrates after drying are solid. In other words, each of the aerosol-forming substrates has a stable size and shape and does not flow. The term "stable" is used herein to mean that the aerosol-forming substrates substantially maintain their shape and mass when exposed to various environmental conditions. As such, the aerosol-forming substrates do not substantially release or absorb water when exposed to standard temperature and pressure conditions with a relative humidity change from about 10 percent to about 60 percent.

This is particularly advantageous since it ensures that the aerosol-forming substrates according to the present invention do not release a liquid phase during storage or transport, for example from the production facility to the point of sale.

When used in an aerosol generating device such as described above, the aerosol forming substrates shown in Examples A, B, C, D and E are heated to a temperature of approximately 375 degrees Celsius. The nicotine and glycerin contained in the film evaporate. The nicotine and glycerin condense to form an inhalable aerosol. The aerosol can then be inhaled by the user. The aerosol forming substrates shrink slightly and their volumes decrease. However, the film remains solid and retains its film shape. The aerosol forming substrates harden slightly and acquire a darker brownish color.

The aerosol-forming substrate shown in Example A comprises a combination of hydroxypropyl methylcellulose and a cellulose-based reinforcing agent. In Example A, the cellulose-based reinforcing agent is cellulose fibers. The aerosol-forming substrate shown in Example A also comprises sodium carboxymethylcellulose, nicotine, glycerol, and a carboxylic acid. In Example A, the carboxylic acid is lactic acid.

The aerosol-forming substrate shown in Example B comprises a combination of hydroxypropyl methylcellulose and a cellulose-based reinforcing agent. In Example B, the cellulose-based reinforcing agent is cellulose fibers. The aerosol-forming substrate shown in Example B contains more cellulose fibers than the aerosol-forming substrate shown in Example A. The aerosol-forming substrate shown in Example B also contains sodium carboxymethylcellulose and glycerin.

The aerosol-forming substrate shown in Example C comprises a combination of hydroxypropyl methylcellulose and a cellulose-based strengthening agent. In Example C, the cellulose-based strengthening agent is cellulose fibers. The aerosol-forming substrate shown in Example C contains less cellulose fibers than the aerosol-forming substrate shown in Example A. The aerosol-forming substrate shown in Example C contains agar rather than sodium carboxymethylcellulose. The aerosol-forming substrate shown in Example C also contains glycerol.

The aerosol-forming substrate shown in Example D contains a combination of hydroxypropyl methylcellulose and two cellulose-based reinforcing agents. In Example D, the cellulose-based reinforcing agents are cellulose fibers and microcrystalline cellulose. The aerosol-forming substrate shown in Example D contains less cellulose fibers than the aerosol-forming substrate shown in Example A. The aerosol-forming substrate shown in Example D contains agar rather than sodium carboxymethylcellulose. The aerosol-forming substrate shown in Example D also contains glycerin.

The aerosol-forming substrate shown in Example E comprises a combination of hydroxypropyl methylcellulose and a cellulose-based strengthening agent. In Example E, the cellulose-based strengthening agent is cellulose powder. The aerosol-forming substrate shown in Example E also comprises sodium carboxymethylcellulose, nicotine, glycerol, and a carboxylic acid. In Example E, the carboxylic acid is lactic acid.

The action of the components of Examples A, B, C and D above, including the action of the cellulose-based reinforcing agents, will now be demonstrated by comparison with an example of a comparative aerosol-forming substrate. The comparative aerosol-forming substrate contains 25.53 percent by weight hydroxypropyl methylcellulose, 6.38 percent by weight agar and 63.81 percent by weight glycerol.

Table 2 shows a comparison of the tensile strength between five examples of aerosol-forming substrate compositions (Examples A, B, C, and D) and a comparative example.

The tensile strength of the example compositions and the comparative composition is measured using the conventional method of stretching a given size test specimen of each composition at a constant rate of elongation until it breaks. A tensile strength tester is attached to the test specimen, which measures the breaking force of the composition. The tensile strength of the test specimen is obtained from the breaking force divided by the width of the specimen.

As shown in Table 2, the aerosol-forming substrate shown in Example A provides an increase in tensile strength of 256 N/m compared to the comparative example. This is an increase in tensile strength of 61%.

The aerosol forming substrate shown in Example B provides an increase in tensile strength of 1159 N/m compared to the comparative example. This is an increase in tensile strength of 275%.

The aerosol forming substrate shown in Example C provides an increase in tensile strength of 409 N/m compared to the comparative example. This is an increase in tensile strength of 97%.

The aerosol forming substrate shown in Example D provides an increase in tensile strength of 778 N/m compared to the comparative example. This is an increase in tensile strength of 185%.

Accordingly, all of the aerosol-forming substrates shown in Examples A, B, C and D exhibit a significant increase in tensile strength compared to the comparative example. The inventors have found that such an increase in the tensile strength of an aerosol-forming substrate can provide a number of advantages, particularly related to subsequent process steps in the manufacture of an aerosol-generating article that contains the aerosol-forming substrate.

For example, after the aerosol-forming substrate is manufactured, it is usually wound onto a reel. Increasing the tensile strength of the aerosol-forming substrate can reduce the breakage of the aerosol-forming substrate due to tension when it is transferred onto the reel.

The subsequent manufacturing step typically involves unwinding the aerosol-forming substrate from a reel and then corrugating the aerosol-forming substrate using corrugating rollers. Increasing the tensile strength of the aerosol-forming substrate can reduce breakage during the corrugating process.

Reducing the degradation of the aerosol-forming substrate during subsequent processing steps can reduce the loss of the aerosol-forming substrate during the manufacturing of an aerosol-forming article containing the aerosol-forming substrate. In addition, if the aerosol-forming substrate is destroyed during processing steps, this can lead to a loss of manufacturing time, and therefore, an increased tensile strength of the aerosol-forming substrate can improve manufacturing time.

Although the aerosol generating substrates shown in Examples C and D exhibit a strong increase in tensile strength, Examples C and D may cause crusting on a portion of the aerosol generating article containing the aerosol generating substrate because they contain agar. The inventors believe that the agar melts when heated (e.g., by an aerosol generating device). The melted agar may form an agglomerate and form around a portion of the aerosol generating article. After the aerosol generating article ceases to be heated, the melted agar may cool and solidify into a crust. This is particularly problematic with an aerosol generating article containing a susceptor, because crusting on the susceptor has been found to reduce heat transfer from the susceptor to the aerosol generating substrate, which may reduce the nicotine level and the volume of aerosol delivered to the user.

The aerosol forming substrates shown in Examples A and B do not contain agar. Instead, the aerosol forming substrates shown in Examples A and B contain sodium carboxymethylcellulose. The inventors have found that an aerosol forming substrate containing carboxymethylcellulose instead of agar reduces crust formation. Indeed, in some examples, the inventors have found that using carboxymethylcellulose instead of agar can completely eliminate the crust formation problem. Reducing and eliminating crust formation, especially crust formation on the susceptor, can result in an increased level of nicotine delivered to the user and an increase in the volume of aerosol generated from the aerosol forming substrate.

Claims (13)

1. An aerosol-forming substrate for use in an aerosol-generating system, wherein the aerosol-forming substrate comprises: at least one aerosol-forming substance, wherein the aerosol-forming substrate has an aerosol-forming substance content of more than 30 percent by weight; hydroxypropyl methylcellulose; and at least one cellulose-based reinforcing agent, wherein at least one cellulose-based reinforcing agent comprises cellulose powder, wherein the aerosol-forming substrate has a cellulose powder content of from 0.5 to 50 percent by weight. 2. An aerosol-forming substrate according to claim 1, containing hydroxypropyl methylcellulose in an amount of from 0.5 to 50 percent by weight. 3. An aerosol-forming substrate according to claim 1 or 2, having a cellulose-based strengthening agent content of more than 0.5 percent by weight. 4. An aerosol-forming substrate according to claim 3, containing a cellulose-based strengthening agent in an amount of from 0.5 to 50 percent by weight. 5. An aerosol-forming substrate according to claim 4, containing a cellulose-based strengthening agent in an amount of from 0.5 to 40 percent by weight. 6. An aerosol-forming substrate according to any one of the preceding claims, wherein at least one cellulose-based reinforcing agent comprises cellulose fibres. 7. An aerosol-forming substrate according to claim 6, containing cellulose fibers in an amount of from 0.5 to 50 percent by weight. 8. An aerosol-forming substrate according to any one of the preceding claims, wherein at least one cellulose-based reinforcing agent comprises microcrystalline cellulose. 9. An aerosol-forming substrate according to claim 8, containing microcrystalline cellulose in an amount of from 0.5 to 50 percent by weight. 10. An aerosol-forming substrate according to any of the preceding claims, comprising carboxymethylcellulose. 11. An aerosol-forming substrate according to claim 10, containing carboxymethylcellulose in an amount of 0.5 to 20 percent by weight. 12. An aerosol-forming substrate according to claim 11, wherein the carboxymethylcellulose comprises sodium carboxymethylcellulose. 13. An aerosol-generating article comprising an aerosol-forming substrate according to any of the preceding claims.