Aerosol-forming substrate in the form of solid unitary body form two particulate materials

Abstract

An aerosol-forming substrate is provided for an aerosol generating system, the aerosol-forming substrate including: a first particulate material; and a second particulate material, the first particulate material being formed from particles having a D50 size of between 2 micrometres and 20 micrometres, and the second particulate material being formed from particles having a D50 size of between 50 micrometres and 80 micrometres, the aerosol-forming substrate being a solid unitary body. An aerosol generating article including the aerosol-forming substrate, and a process for manufacturing the aerosol-forming substrate, are also provided.

1 .- 15 . (canceled) 
     
     
         16 . An aerosol-forming substrate for an aerosol generating system, the aerosol-forming substrate comprising:
 a first particulate material; and   a second particulate material,   the first particulate material being formed from particles having a D50 size of between 2 micrometres and 20 micrometres, and the second particulate material being formed from particles having a D50 size of between 50 micrometres and 80 micrometres,   wherein the aerosol-forming substrate is a solid unitary body.   
     
     
         17 . The aerosol-forming substrate according to  claim 16 , wherein a ratio of a mass of the first particulate material to a mass of the second particulate material in the aerosol-forming substrate is no more than 1:2. 
     
     
         18 . The aerosol-forming substrate according to  claim 16 , wherein the first particulate material is formed from particles having a D50 size of 10 micrometres, and the second particulate material is formed from particles having a D50 size of 59 micrometres. 
     
     
         19 . The aerosol-forming substrate according to  claim 16 , wherein the first particulate material is formed from particles having a D95 size of between 10 micrometres and 60 micrometres, and the second particulate material is formed from particles having a D95 size of between 80 micrometres and 130 micrometres. 
     
     
         20 . The aerosol-forming substrate according to  claim 19 , wherein the first particulate material is formed from particles having a D95 size of 33 micrometres, and the second particulate material is formed from particles having a D95 size of 116 micrometres. 
     
     
         21 . The aerosol-forming substrate according to  claim 16 , wherein the first particulate material is formed from particles having a diameter of between 5 micrometres and 40 micrometres, and the second particulate material is formed from particles having a diameter of between 50 micrometres and 250 micrometres. 
     
     
         22 . The aerosol-forming substrate according to  claim 16 , wherein the first particulate material and the second particulate material are formed from the same material. 
     
     
         23 . The aerosol-forming substrate according to  claim 16 , wherein at least one of the first particulate material and the second particulate material comprise one or more of cellulose and microcrystalline cellulose (MCC). 
     
     
         24 . The aerosol-forming substrate according to  claim 16 , further comprising a binder. 
     
     
         25 . The aerosol-forming substrate according to  claim 16 , further comprising one or more of nicotine, lactic acid, and sucrose. 
     
     
         26 . The aerosol-forming substrate according to  claim 16 ,
 further comprising cellulose strengthening fibres,   wherein the cellulose strengthening fibres have a D50 size of between 0.8 millimetres and 1.5 millimetres.   
     
     
         27 . The aerosol-forming substrate according to  claim 16 , wherein a ratio of a mass of the first particulate material to a mass of the second particulate material in the aerosol-forming substrate is at least 1:5. 
     
     
         28 . The aerosol-forming substrate according to  claim 16 , wherein the aerosol-forming substrate does not comprise tobacco. 
     
     
         29 . An aerosol generating article comprising an aerosol-forming substrate according to  claim 16 . 
     
     
         30 . A process for manufacturing an aerosol-forming substrate, the process comprising:
 providing a first particulate material, the first particulate material being formed from particles having a D50 size of between 2 micrometres and 20 micrometres;   providing a second particulate material, the second particulate material being formed from particles having a D50 size of between 50 micrometres and 80 micrometres;   mixing the first particulate material and the second particulate in an aqueous solution to form a slurry;   casting the slurry; and   drying the cast slurry to form a solid substrate.