An aerosol-forming substrate for use in a heated aerosol-generating article comprises expanded graphite particles. Expanded graphite particles have high thermal conductivity and low density and may improve efficiency of aerosol delivery from the substrate.

There is provided an aerosol-forming substrate comprising, on a dry weight basis: between 10 and 90 wt % thermally conductive particles, each thermally conductive particle of the thermally conductive particles having a thermal conductivity of at least 1 W/(mK) in at least one direction at 25 degrees Celsius; between 7 and 60 wt % of an aerosol former; between 2 and 20 wt % of fibres; and between 2 and 10 wt % of a binder. The aerosol-forming substrate has a thermal conductivity of at least 0.22 W/(mK) in at least one direction at 25 degrees Celsius. There is also provided an aerosol-generating article comprising the aerosol-forming substrate and a method of forming the aerosol-forming substrate.

A smoking article (10) incorporates a tobacco substrate including tobacco having a tobacco density of 150 mg/cm.sup.3 or less and a hardness of 60% or greater. The tobacco substrate can include a tobacco aerogel (20).

There is provided a heated aerosol-generating article for producing an inhalable aerosol, the heated aerosol-generating article including: an aerosol-forming substrate that is a homogenized tobacco material including tobacco, a fat having a melting point between 20 C. and 50 C., and one or more aerosol-formers, the homogenized tobacco material containing at least 60% tobacco on a dry weight basis. A homogenized tobacco material is also provided.

A smoking article formed from a tobacco material that includes tobacco non-isometric precipitated calcium carbonate microparticles is provided. The non-isometric microparticles typically have a mean diameter of from about 50 nanometers to about 3 micrometers, in some embodiments from about 80 nanometers to about 1 micrometer, in some embodiments from about 100 nanometers to about 400 nanometers, and in some embodiments, from about 200 nanometers to about 300 nanometers. Such non-isometric particles may have an elongated morphology so that the length of the microparticles is greater than the diameter. This may be characterized by the aspect ratio of the microparticles (length divided by width), which is typically from about 1 to about 15, in some embodiments from about 2 to about 12, and in some embodiments, from about 3 to about 10. For example, the average length of the microparticles may range from about 100 nanometers to about 8 micrometers, in some embodiments from about 300 nanometers to about 5 micrometers, in some embodiments from about 500 nanometers to about 4 micrometers, and in some embodiments, from about 1 micrometer to about 3 micrometers.

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

The disclosure provides a solventless method of producing coated botanical substrates by (i) uniformly coating a known exact amount of an active ingredient on the botanical substrates until the ingredient is substantially adsorbed to the surface of the botanical substrate to produce a homogeneous primary coating of the ingredient on the botanical substrates, and optionally (ii) substantially incorporating a flavoring agent with the surface of the plurality of botanical substrates coated with the ingredient.

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.

A smoking article according to an example embodiment includes a medium receiver filled with a plurality of medium granules, a humectant receiver on one side of the medium receiver and configured to generate an aerosol and a filter on the other side of the medium receiver. The plurality of medium granules have an atypical shape.

A tobacco-flavor-releasing material includes granules which contain (a) a ground tobacco material, (b) water, (c) a moisturizing agent includes a polyhydric alcohol, (d) at least one pH-adjusting agent selected from the group consisting of potassium carbonate and sodium hydrogencarbonate, and (e) at least one binder selected from the group consisting of pullulan and hydroxypropyl cellulose.