Aerosol generating article having one or more flaps

Abstract

An aerosol-generating article (2100) is provided, extending longitudinally between a first end (2101) and a second end (2102). At least one flap (2160, 2130) is located at one of the first and second ends. At least one flap is configured to fold so as to overlap at least a portion of the end on which the flap is located.

Description

Technical Field

[0001] The present disclosure relates to aerosol-generating articles. The present disclosure also relates to a package having a plurality of aerosol-generating articles and a container for receiving the plurality of aerosol-generating articles.

Background Art

[0002] In the field of aerosol-generating articles for delivering an aerosol to a user, such aerosol-generating articles are known to have a circular cross-section and extend between a first open end and a second open end that face each other.

Summary of the Invention

Means for Solving the Problems

[0003] In a first aspect of the present disclosure, an aerosol-generating article is provided that extends in a longitudinal direction between a first end and a second end that face each other. The aerosol-generating article may comprise a peripheral wall. The peripheral wall may be lens-shaped in an axial cross-section.

[0004] The lens-shaped cross-section is associated with a shape having a thickness dimension that is smaller than the width dimension. Thus, in contrast to an aerosol-generating article having a cylindrical cross-section, the aerosol-generating article of the present disclosure has a flat cross-sectional profile, i.e., the ratio of the thickness of the aerosol-generating article to the width of the aerosol-generating article is less than 1. The use of a lens-shaped cross-section reduces the likelihood that the article will roll along its outer surface when placed on a flat surface. The reduced thickness associated with the use of a lens-shaped cross-section may also facilitate heating the aerosol-generating article uniformly over its thickness compared to an aerosol-generating article having a peripheral wall of the same circumferential length but a circular axial cross-section. It will be understood that the "thickness" of the aerosol-generating article may also be referred to as the "height" of the aerosol-generating article.

[0005] The first end may form the distal end of the aerosol-generating article. The second end may form the proximal or oral end of the aerosol-generating article, through which the aerosol may exit the article during use and be inhaled by the user. When the user inhales the second end (proximal or oral end), the airflow may be drawn out through the first end (distal end) and flow downstream toward the second end. In this context, the first end may form the upstream end of the aerosol-generating article, and the second end may form the downstream end of the aerosol-generating article. The first and second ends may also be referred to as the front end and rear end of the aerosol-generating article, respectively.

[0006] The peripheral wall may have opposing first and second convex portions. The opposing ends of the first convex portion may coincide with the corresponding opposing end of the second convex portion to define a pair of laterally opposing edges of the peripheral wall. The opposing first and second convex portions facilitate providing the peripheral wall with a contour similar to that of a biconvex lens.

[0007] At each of the two laterally opposing edges of the peripheral wall, the outer surface of the peripheral wall preferably has a radius of curvature of less than 2 millimeters, less than 1 millimeter, less than 0.5 millimeters, or less than 0.25 millimeters. The use of such small values ​​for the radius of curvature at the laterally opposing edges of the peripheral wall can ensure that the sides of the aerosol-generating article are well defined.

[0008] Advantageously, the peripheral wall may include a pair of folds that define a pair of laterally opposing edges of the peripheral wall.

[0009] At each of the pair of laterally opposing edges of the perimeter wall, the acute angle between the first tangent to the outer surface of the first convex portion and the second tangent to the outer surface of the second convex portion is preferably in the range of 15 to 110 degrees, or 15 to 90 degrees, or 15 to 75 degrees, or 15 to 65 degrees, or 15 to 55 degrees, or 15 to 45 degrees, or 15 to 35 degrees, or 15 to 25 degrees. The use of smaller values ​​for the acute angle provides a sharper, better defined geometric profile on the outer surface of the perimeter wall at the positions of the pair of laterally opposing edges of the perimeter wall.

[0010] At an intermediate position between a pair of laterally opposing edges of the peripheral wall, the radii of curvature of the inner surfaces of the first and second convex portions may be between 100 mm and 500 mm.

[0011] The aerosol-generating article may have a width of 20 millimeters or less. Preferably, the width of the aerosol-generating article is within the range of 14 millimeters to 20 millimeters.

[0012] The aerosol-generating article may have a thickness of 8 mm or less. Preferably, the thickness of the aerosol-generating article is within the range of 3 mm to 8 mm, 3 mm to 6 mm, or 3 mm to 5 mm. Preferably, the thickness of the aerosol-generating article is about 4 mm.

[0013] The aerosol-generating article may further comprise at least one flap located at one of the first and second ends. The at least one flap may be configured to fold over at least a portion of the end on which the flap is located.

[0014] At least one flap may be configured to be folded by the user.

[0015] At least one flap may be configured to fold so as to cover at least a portion of the opening defined at the end where the flap is located, for example, to cover the opening and / or to extend into the opening.

[0016] The flap may be connected to the article by a fold, for example, a score line. The flap may be configured to fold along a fold such that the flap overlaps with at least a portion of the opening. The flap may be configured to fold along a fold such that the edge of the flap is located within the opening, for example, the edge of the flap may be in contact with the inner wall of the aerosol-generating article, such as the inner wall of the chamber accessed through the opening. The inner wall of the aerosol-generating article may form part of the peripheral wall.

[0017] The flap may have at least one opening and / or be formed of an air-permeable material. If such a flap is positioned at the mouth end of an aerosol-generating article, the use of an opening and / or the use of an air-permeable material for the flap may allow a user to inhale aerosols from the aerosol-generating article through the flap at the mouth end.

[0018] In a second aspect of the present disclosure, an aerosol-generating article is provided that extends longitudinally between opposing first and second ends, for example, the aerosol-generating article may be as described in any of the preceding paragraphs. The aerosol-generating article may include a peripheral wall, which may define a flat shape that is contracted in an axial cross-section.

[0019] As can be understood from subsequent paragraphs of this disclosure (for example, as listed below for a third aspect of this disclosure), the aerosol-generating articles outlined in the first and second aspects of this disclosure may be the same article but relate to articles in different states. Preferably, the first aspect of this disclosure relates to an aerosol-generating article in an expanded state, and the second aspect of this disclosure relates to an aerosol-generating article in a contracted state. More specifically, the area enclosed by the peripheral wall is larger in the expanded state than in the contracted state. The expanded state may be associated with an aerosol-generating article that is ready for (or in use by) a user. In contrast, the flat contracted state may be associated with an aerosol-generating article that is suitable for efficient packaging or storage of multiple aerosol-generating articles, as the contracted cross-section of the article allows for more efficient packaging of different articles side by side or end to end.

[0020] Conveniently, the opposing inward-facing surfaces of the peripheral walls are in surface contact with each other. This surface contact facilitates minimizing the thickness of the cross-section defined by the peripheral walls of the aerosol-generating article, thereby facilitating the efficient packaging of different articles.

[0021] The opposing outward-facing surfaces of the surrounding walls may be parallel to each other.

[0022] The opposing outward-facing surfaces of the surrounding walls may generally be flat.

[0023] The aerosol-generating article preferably has a thickness of 5 mm or less. The thickness of the aerosol-generating article may be in the range of 0.5 mm to 5 mm, or 0.5 mm to 3 mm, or 0.5 mm to 2 mm, or 0.5 mm to 1.5 mm. The aerosol-generating article preferably has a thickness of about 1 mm.

[0024] The contracted flat shape of the peripheral wall may be due to the flattening of the tubular member. As an example, the tubular member may be the peripheral wall of an aerosol-generating article or an aerosol-generating article.

[0025] In a third aspect of the present disclosure, an aerosol-generating article extending in the longitudinal direction between an opposing first end and a second end is provided. As an example, the aerosol-generating article may be as described in any of the preceding paragraphs. The aerosol-generating article may comprise a peripheral wall. The peripheral wall is configured to be deformable, resulting in a contraction of the width of the aerosol-generating article and an accompanying expansion of the thickness of the aerosol-generating article, thereby enabling the aerosol-generating article to transition from a contracted first state to an expanded second state. In the expanded second state, the area enclosed by the peripheral wall increases relative to the contracted first state.

[0026] The contracted first state may be particularly suitable for the efficient packaging of multiple different aerosol-generating articles, as it can help reduce the size of the gaps between adjacent articles compared to conventional aerosol-generating articles having a circular cross-section (e.g., in a side-by-side relationship). A user can take an unused aerosol-generating article in the contracted first state and compress the opposing lateral surfaces of the peripheral wall towards each other to transition the article to the expanded second state. The larger area enclosed by the peripheral wall in the expanded second state provides an improved airflow through the article compared to when the article is in the contracted first state, thereby facilitating the inhalation of the article through the second end of the article.

[0027] In the contracted first state, it is preferred that the opposing inward-facing surfaces of the peripheral wall are in surface contact with each other. As described above, bringing the opposing inward-facing surfaces of the peripheral wall into surface contact with each other facilitates minimizing the thickness of the cross-section defined by the peripheral wall of the aerosol-generating article, thereby facilitating the efficient packaging of different articles.

[0028] In the contracted first state, the opposing outward-facing surfaces of the peripheral wall may be parallel to each other.

[0029] In the contracted first state, the opposing outer surfaces of the peripheral wall may generally be planar.

[0030] Advantageously, in the expanded second state, the peripheral wall of the aerosol-generating article may be lens-shaped in an axial cross-section. This may provide the same advantages associated with the first aspect of the present disclosure, as outlined in the preceding paragraph. The peripheral wall may include opposing first and second portions. The opposing ends of the first portion may coincide with the corresponding opposing ends of the second portion to define a pair of edges that oppose each other in the lateral direction of the peripheral wall. The peripheral wall may be adapted such that deformation of the pair of edges that oppose each other in the lateral direction introduces or increases the separation between the opposing first and second portions of the peripheral wall at a position between the pair of edges that oppose each other in the lateral direction, thereby causing the aerosol-generating article to transition between the contracted first state and the expanded second state.

[0031] The aerosol-generating article preferably includes an aerosol-forming substrate, and preferably forms at least a part of the peripheral wall. The aerosol-forming substrate may be configured to generate an inhalable aerosol when heated. More specifically, the aerosol-forming substrate may be configured to generate an aerosol when subjected to a heating level sufficient to heat the aerosol-forming substrate but not to ignite or combust it. The aerosol-forming substrate preferably includes an aerosol-forming body.

[0032] Advantageously, the peripheral wall may include both the aerosol-forming substrate and a support substrate. "Support substrate" means a material configured to provide an appropriate level of flexural rigidity to the aerosol-generating article. The support substrate preferably has a higher flexural rigidity than the aerosol-forming substrate.

[0033] The peripheral wall may comprise at least one sheet of aerosol-forming substrate and at least one sheet of support substrate. Each sheet is preferably formed as a single layer, but instead may be formed as two or more layers stacked on top of each other to form each sheet. The peripheral wall may define a laminated structure formed from both at least one sheet of aerosol-forming substrate and at least one sheet of support substrate.

[0034] The peripheral wall may comprise a band of aerosol-forming substrate. The peripheral wall may comprise a band of support substrate. If the peripheral wall comprises both a band of aerosol-forming substrate and a band of support substrate, conveniently, the aerosol-forming substrate band radially surrounds the band of support substrate or is surrounded by the band of support substrate.

[0035] Advantageously, the support base may be made of cardboard. Cardboard is preferred due to its bending rigidity.

[0036] A fourth aspect of the present disclosure provides an aerosol-generating article extending between opposing first and second ends, for example, the aerosol-generating article may be as described in any of the preceding paragraphs. The aerosol-generating article may include a peripheral wall, the peripheral wall comprising at least one support substrate sheet. A fold may be defined within at least one support substrate sheet to define a folded support substrate sheet. A first portion of the folded support substrate sheet may be folded around the fold and overlap a second portion of the folded support substrate sheet to define a closed path corresponding to the peripheral wall.

[0037] The first portion of the folded support base sheet may extend over the first half of the circumferential length of the peripheral wall, and the second portion of the folded support base sheet may extend over the second half of the circumferential length of the peripheral wall.

[0038] Preferably, the free ends of the first and second portions of the folded support base sheet may be aligned with each other to define a closing path. Alternatively, the free ends of the first and second portions of the folded sheet may overlap with each other to define a closing path.

[0039] The peripheral wall preferably further comprises at least one sheet of aerosol-forming substrate. The at least one sheet of aerosol-forming substrate may include either or both of i) an outer arrangement of one or more sheets of aerosol-forming substrate, and ii) an inner arrangement of one or more sheets of aerosol-forming substrate. The outer arrangement of one or more sheets of aerosol-forming substrate may be arranged to cover (preferably in surface contact with) the outward-facing surfaces of both the first and second portions of the folded support substrate sheet. Similarly, the inner arrangement of one or more sheets of aerosol-forming substrate may be arranged to cover (preferably in surface contact with) the inward-facing surfaces of both the first and second portions of the folded support substrate sheet.

[0040] The outer configuration may include a common sheet of aerosol-forming substrate arranged to cover (preferably in surface contact with) the outward-facing surfaces of both the first and second portions of the folded support substrate sheet. Similarly, the inner configuration may include a common sheet of aerosol-forming substrate arranged to cover (preferably in surface contact with) the inward-facing surfaces of both the first and second portions of the folded support substrate sheet.

[0041] Alternatively, the outer configuration may instead comprise a first outer sheet of aerosol-forming substrate arranged to cover (preferably in surface contact with) the outward-facing surface of a first portion of the folded support substrate sheet, and a second outer sheet of aerosol-forming substrate arranged to cover (preferably in surface contact with) the outward-facing surface of a second portion of the folded support substrate sheet. Similarly, the inner configuration may comprise a first inner sheet of aerosol-forming substrate arranged to cover (preferably in surface contact with) the inward-facing surface of a first portion of the folded support substrate sheet, and a second inner sheet of aerosol-forming substrate arranged to cover (preferably in surface contact with) the inward-facing surface of a second portion of the folded support substrate sheet.

[0042] A fifth aspect of the present disclosure provides an aerosol-generating article extending between opposing first and second ends, for example, the aerosol-generating article may be as described in any of the preceding paragraphs. The aerosol-generating article may include a peripheral wall comprising at least one support substrate sheet. The at least one support substrate sheet may include a first support substrate sheet and a second support substrate sheet arranged opposite to each other. The laterally opposed edges of the first support substrate sheet and the second support substrate sheet may be aligned with each other to define a laterally opposed edge of the peripheral wall, so that the first support substrate sheet and the second support substrate sheet define a closed path corresponding to the peripheral wall.

[0043] The first sheet of the support base may extend over the first half of the circumference of the peripheral wall, and the second sheet of the support base may extend over the second half of the circumference of the peripheral wall.

[0044] The peripheral wall preferably further comprises at least one sheet of aerosol-forming substrate. The at least one sheet of aerosol-forming substrate may include either or both of the following: i) an external arrangement of one or more sheets of aerosol-forming substrate, and ii) an internal arrangement of one or more sheets of aerosol-forming substrate. The external arrangement of one or more sheets of aerosol-forming substrate may be arranged to cover (preferably in surface contact with) the outward-facing surfaces of both the first sheet and the second sheet of the support substrate. Similarly, the internal arrangement of one or more sheets of aerosol-forming substrate may be arranged to cover (preferably in surface contact with) the inward-facing surfaces of both the first sheet and the second sheet of the support substrate.

[0045] The outer configuration may include a common aerosol-forming substrate sheet arranged to cover (preferably in surface contact with) the outward-facing surfaces of both the first sheet and the second sheet of the support substrate. Similarly, the inner configuration may include a common aerosol-forming substrate sheet arranged to cover (preferably in surface contact with) the inward-facing surfaces of both the first sheet and the second sheet of the support substrate.

[0046] Alternatively, the outer configuration may comprise a first outer sheet of an aerosol-forming substrate arranged to cover (preferably in surface contact with) the outward-facing surface of the first sheet of the support substrate, and a second outer sheet of an aerosol-forming substrate arranged to cover (preferably in surface contact with) the outward-facing surface of the second sheet of the support substrate. Similarly, the inner configuration may comprise a first inner sheet of an aerosol-forming substrate arranged to cover (preferably in surface contact with) the inward-facing surface of the first sheet of the support substrate, and a second inner sheet of an aerosol-forming substrate arranged to cover (preferably in surface contact with) the inward-facing surface of the second sheet of the support substrate.

[0047] In a sixth aspect of the present disclosure, an aerosol-generating article is provided that extends between opposing first and second ends, for example, the aerosol-generating article may be as described in any of the preceding paragraphs. The aerosol-generating article may include a peripheral wall comprising at least one sheet of an aerosol-forming substrate. A fold may be defined within at least one sheet of the aerosol-forming substrate to define a folded sheet of the aerosol-forming substrate. A first portion of the folded sheet of the aerosol-forming substrate may be folded around a fold and overlap a second portion of the folded sheet of the aerosol-forming substrate to define a closed path corresponding to the peripheral wall.

[0048] The first portion of the folded aerosol-forming substrate sheet may extend over the first half of the circumferential length of the peripheral wall, and the second portion of the folded aerosol-forming substrate sheet may extend over the second half of the circumferential length of the peripheral wall.

[0049] Preferably, the free ends of the first and second portions of the folded aerosol-forming substrate sheet can be aligned with each other to define a closed pathway. However, alternatively, the free ends of the first and second portions of the folded sheet can overlap with each other, thereby defining a closed pathway.

[0050] The peripheral wall preferably further comprises at least one support substrate sheet. The at least one support substrate sheet may include one or both of the following: i) an external arrangement of one or more support substrate sheets, and ii) an internal arrangement of one or more support substrate sheets. The external arrangement of one or more support substrate sheets may be arranged to cover (preferably in surface contact with) the outward-facing surfaces of both the first and second portions of the folded aerosol-forming substrate sheet. Similarly, the internal arrangement of one or more support substrate sheets may be arranged to cover (preferably in surface contact with) the inward-facing surfaces of both the first and second portions of the folded aerosol-forming substrate sheet.

[0051] The outer configuration may include a common sheet of support substrates arranged to cover (preferably in surface contact with) the outward-facing surfaces of both the first and second portions of the folded aerosol-forming substrate sheet. Similarly, the inner configuration may include a common sheet of support substrates arranged to cover (preferably in surface contact with) the inward-facing surfaces of both the first and second portions of the folded aerosol-forming substrate sheet.

[0052] Alternatively, the outer configuration may instead comprise a first outer sheet of a support base arranged to cover (preferably in surface contact with) the outward-facing surface of a first portion of the folded aerosol-forming substrate sheet, and a second outer sheet of the support base arranged to cover (preferably in surface contact with) the outward-facing surface of a second portion of the folded aerosol-forming substrate sheet. Similarly, the inner configuration may comprise a first inner sheet of a support base arranged to cover (preferably in surface contact with) the inward-facing surface of a first portion of the folded aerosol-forming substrate sheet, and a second inner sheet of the support base arranged to cover (preferably in surface contact with) the inward-facing surface of a second portion of the folded aerosol-forming substrate sheet.

[0053] A seventh aspect of the present disclosure provides an aerosol-generating article extending between opposing first and second ends, for example, the aerosol-generating article may be as described in any of the preceding paragraphs. The aerosol-generating article may include a peripheral wall comprising at least one sheet of an aerosol-forming substrate. The at least one sheet of the aerosol-forming substrate may comprise a first sheet and a second sheet of the aerosol-forming substrate arranged opposite to each other. The laterally opposed edges of the first and second sheets of the aerosol-forming substrate may be aligned with each other to define the laterally opposed edges of the peripheral wall, and the first and second sheets of the aerosol-forming substrate thereby define a closed path corresponding to the peripheral wall.

[0054] The first sheet of the aerosol-forming substrate may extend over the first half of the circumferential length of the peripheral wall, and the second sheet of the aerosol-forming substrate may extend over the second half of the circumferential length of the peripheral wall.

[0055] The peripheral wall preferably further comprises at least one support substrate sheet. The at least one support substrate sheet may include one or both of the following: i) an external arrangement of one or more support substrate sheets, and ii) an internal arrangement of one or more support substrate sheets. The external arrangement of one or more support substrate sheets may be arranged to cover (preferably in surface contact with) the outward-facing surfaces of both the first and second sheets of the aerosol-forming substrate. Similarly, the internal arrangement of one or more support substrate sheets may be arranged to cover (preferably in surface contact with) the inward-facing surfaces of both the first and second sheets of the aerosol-forming substrate.

[0056] The outer configuration may include a common sheet of support substrate arranged to cover (preferably in surface contact with) the outward-facing surfaces of both the first and second sheets of the aerosol-forming substrate. Similarly, the inner configuration may include a common sheet of support substrate arranged to cover (preferably in surface contact with) the inward-facing surfaces of both the first and second sheets of the aerosol-forming substrate.

[0057] Alternatively, the outer configuration may comprise a first outer sheet of a support base arranged to cover (preferably in surface contact with) the outward-facing surface of the first sheet of the aerosol-forming substrate, and a second outer sheet of the support base arranged to cover (preferably in surface contact with) the outward-facing surface of the second sheet of the aerosol-forming substrate. Similarly, the inner configuration may comprise a first inner sheet of a support base arranged to cover (preferably in surface contact with) the inward-facing surface of the first sheet of the aerosol-forming substrate, and a second inner sheet of the support base arranged to cover (preferably in surface contact with) the inward-facing surface of the second sheet of the aerosol-forming substrate.

[0058] In other embodiments, the peripheral wall of the aerosol-generating article may not have a support substrate separate from the aerosol-forming substrate. Rather, the aerosol-forming substrate may instead function as the sole or primary source of bending stiffness for the peripheral wall of the aerosol-generating article.

[0059] In one exemplary embodiment, the peripheral wall may include or consist of strips of aerosol-forming substrate, the strips of aerosol-forming substrate configured to provide all or at least most of the bending stiffness of the peripheral wall.

[0060] The aerosol-forming substrate band preferably comprises at least one sheet of the aerosol-forming substrate. Advantageously, a fold may be defined within at least one sheet of the aerosol-forming substrate to define a folded sheet of the aerosol-forming substrate. A first portion of the folded aerosol-forming substrate sheet may fold around a fold and overlap a second portion of the folded aerosol-forming substrate sheet to define a closed path corresponding to a peripheral wall. Preferably, the first portion of the folded aerosol-forming substrate sheet extends over a first half of the circumferential length of the peripheral wall, and the second portion of the folded aerosol-forming substrate sheet extends over a second half of the circumferential length of the peripheral wall.

[0061] In any embodiment of the aerosol generating article described herein, the peripheral wall of the aerosol generating article may be provided with a wrapper, which defines the outer surface of the aerosol generating article. The wrapper may include cigarette paper or consist of cigarette paper. The wrapper may include a sheet of metal foil or be formed as a laminate of paper and metal foil, the metal foil may include aluminum.

[0062] In an eighth aspect of the present disclosure, an aerosol-generating article is provided that extends longitudinally between opposing first and second ends, for example, the aerosol-generating article may be as described in any of the preceding paragraphs. The aerosol-generating article may include a peripheral wall. The peripheral wall may include a support substrate. At least a portion of the axial length of the peripheral wall may be configured to be permeable to air. The arrangement of one or more sheets of the aerosol-forming substrate may be positioned to radially surround the air-permeable portion of the axial length of the peripheral wall. The air permeability of the support substrate allows vapors emitted from the aerosol-forming substrate upon heating to be carried across the peripheral wall into the interior of the aerosol-generating article and, for example, inhaled by a user.

[0063] Conveniently, the arrangement of one or more sheets of the aerosol-forming substrate may be configured to form a sleeve that radially surrounds the air-permeable portion of the peripheral wall in the axial direction.

[0064] The arrangement of one or more sheets of the aerosol-forming substrate is preferably positioned closer to the first end of the aerosol-generating article than to the second end of the article. The second end of the article may define the mouth end of the article. In this way, a portion of the axial length of the aerosol-generating article at or near the mouth end does not contain the aerosol-forming substrate, thereby allowing the user to hold the article near the mouth end while the arrangement of one or more sheets of the aerosol-forming substrate is heating, reducing the possibility of burning fingers.

[0065] Air permeability may be provided in a variety of different ways. For example, an air permeable portion of the peripheral wall along its axial length may comprise multiple openings. The openings may have any suitable cross-sectional shape, such as circular, elliptical, square, triangular, or any other suitable shape. In another embodiment, the air permeable portion of the peripheral wall along its axial length may comprise an air permeable material, such as a porous material.

[0066] The air-permeable portion of the support substrate strip along its axial length may contain an air-permeable material. In this way, the entire air-permeable portion of the support substrate strip along its axial length can contribute to allowing vapor emitted from the aerosol-forming substrate upon heating to pass into the interior of the aerosol-generating article. Conveniently, the air-permeable material is a porous material.

[0067] The aerosol-generating article may have a length of 100 mm or less, or 90 mm or less. Preferably, the length of the aerosol-generating article is within the range of 20 mm to 100 mm, or 25 mm to 100 mm, or 30 mm to 100 mm, or 35 mm to 100 mm, or 40 mm to 100 mm.

[0068] In a ninth aspect of the present disclosure, an aerosol-generating article is provided that extends along its longitudinal axis between a first end and a second end, for example, the aerosol-generating article may be as described in any of the preceding paragraphs. At least one flap may be located at one of the first and second ends. At least one flap may be configured to fold so as to overlap at least a portion of the end in which the flap is located. Thus, aspects of the present invention may provide an aerosol-generating article that extends along its longitudinal axis between a first end and a second end, where at least one flap is located at one of the first and second ends, and at least one flap is configured to fold so as to overlap at least a portion of the end in which the flap is located.

[0069] The flap may be formed from any suitable material. For example, the flap may include or be formed from paper or cardboard material. The flap may include or be formed from a sheet of aerosol-forming material or a material incorporating the aerosol-forming material. The flap may act to close or cover the edge of the aerosol-generating article. Preferably, at least one flap is configured to be folded by the user. Preferably, at least one flap is configured to fold so as to cover at least a portion of an opening defined at the edge where the at least one flap is located, for example, to cover the opening and / or to extend into the opening.

[0070] When folded into an unfolded position that overlaps with at least a portion of the edge of the article, at least one flap may provide some structural rigidity to the article. Furthermore, the flap may be configured to function as a filter element that helps prevent the user from inhaling particles from inside the article. Furthermore, the flap may be configured to provide a certain draw resistance when the user is sucking smoke from the article.

[0071] At least one flap comprises flaps, for example, a first flap or a second flap. The flap may be connected to the article at a fold. The fold may be a score line. Preferably, the flap is configured to fold at the fold. The flap may extend between the fold and the flap edge, for example, the flap may extend away from the article between the fold and the flap edge.

[0072] Advantageously, the fold may be curved, for example, concave with respect to the longitudinal dimension of the article. By folding the flap along such a curved fold, the geometric shape of the fold can effectively lock the flap in the unfolded position and improve the structural rigidity of the article after the flap is folded. Flaps folded along such curved folds are known from their use in boxes, such as so-called pillow boxes.

[0073] The flap edge may be curved, for example, convex with respect to the longitudinal dimension of the article. The curved edge can help the flap edge engage with a curved opening at the end of the article. For example, the opening of the article may have a curved cross section, for example, a lenticular or elliptical cross section, and the flap edge may be shaped to fit this curved opening when the flap is folded to overlap or close the opening.

[0074] The fold is preferably located adjacent to an opening defined at the edge where the flap is positioned. For example, the flap may be configured to fold along the fold such that the flap overlaps with or covers at least a portion of the opening. The flap may be configured to fold along the fold such that the flap edge is located within the opening. For example, the flap edge may be in contact with the inner wall of the aerosol generating article, for example, the inner wall of the chamber accessed through the opening. The flap edge may be in contact with the inner portion of the peripheral wall of the aerosol generating article.

[0075] In a preferred embodiment, the flap or each flap is arc-shaped. For example, the flap or each flap may be lens-shaped or elliptical. The shape of the flap may be defined by the flap fold and flap edge.

[0076] At least one flap may be permeable to air. Air can flow around the edge of the flap, but precise control of the airflow may be possible by configuring the flap to be air-permeable. Thus, at least one through-hole may be defined through at least one flap. Alternatively, or additionally, at least one flap may include an air-permeable material, such as a porous material, such as a filter material. Air may flow through such an air-permeable material, for example, when a user sucks on an item.

[0077] In some embodiments, at least one through-hole may be defined within at least one flap, and the air-permeable material may be coupled to the flap overlapping the through-hole so that air can pass through at least one through-hole and the air-permeable flap.

[0078] Optionally, the through-hole defined through the flap may have a diameter of 0.1 mm to 1 mm, for example, 0.2 mm to 0.75 mm, or for example, 0.3 mm to 0.5 mm.

[0079] Optionally, the flap may provide a draw-out resistance (RTD) of 10 mmH2O to 50 mmH2O with respect to the air passing through the flap. The aerosol-generating article described may have a draw-out resistance (RTD) of 10 mmH2O to 50 mmH2O with respect to the air passing through the article between the first and second ends.

[0080] The at least one flap described above may be more than one flap. For example, the at least one flap may be two flaps. The two flaps may be described as an upper flap and a lower flap. Thus, the article may comprise an upper flap attached to the aerosol-generating article at an upper fold and a lower flap attached to the aerosol-generating article at a lower fold. The lower flap may be configured to fold upward, and the upper flap may be configured to fold downward.

[0081] Both the upper and lower flaps may overlap with at least a portion of the edge where the flaps are located. For example, both the upper and lower flaps may overlap with, straddle, or close an opening defined at the edge where the flaps are located. When folded, both the upper and lower flaps may overlap with each other and overlap with at least a portion of the edge where the flaps are located.

[0082] The upper and lower flaps may be configured to engage with each other when folded so as to overlap at least a portion of the edge in which the flaps are located. For example, a tab may be defined on one of the upper or lower flaps. The tab may engage with a slot defined on the other of the upper or lower flap when the flap is folded. Such engagement may help to secure the flaps in their folded positions.

[0083] The term "at least one flap" may refer to a single or isolated flap.

[0084] At least one flap may be at least one first end flap located at the first end of the article, and at least one first end flap is configured to fold so as to overlap at least a portion of the opening defined at the first end. Thus, at least one first end flap may be configured to fold so as to at least partially cover the opening defined at the first end, for example, to cover or close the opening defined at the first end, or to extend into the opening defined at the first end. Preferably, at least one first end flap is configured to be folded by the user so as to straddle the opening. At least one flap may be at least one second end flap located at the second end, and at least one second end flap is configured to fold so as to overlap at least a portion of the opening defined at the second end. Thus, at least one second end flap may be configured to fold so as to at least partially cover the opening defined at the second end, for example, to cover or close the opening defined at the second end, or to extend into the opening defined at the second end. Preferably, at least one second end flap is configured to be folded by the user so as to straddle the opening.

[0085] The aerosol-generating article may include at least one first end flap located at the first end and at least one second end flap located at the second end.

[0086] The first end may be called the distal end. The second end may be called the proximal end or oral end, and may be on the opposite side from the distal end. If the flap is located at the oral end, the flap may function to increase the structural rigidity of the article, for example, to resist pressure from the user's lips placed over the oral end. The flap at the oral end may also be configured to function as a mouthpiece filter.

[0087] The airflow path is preferably defined within the article through an inlet or opening located at one of the first and second ends of the article. The airflow inlet may be defined through the side wall of the article, for example, through the peripheral wall. The side wall inlet may be in addition to, or instead of, an inlet located at the end of the article. The airflow path is preferably defined outside the article through an outlet or opening located at one of the first and second ends of the article. The outlet may be located at the mouth-side end of the article, configured to be placed in the mouth of a user. In a preferred embodiment, an airflow path is defined that enters the article through an opening defined at the first end of the article and exits the article through an opening defined at the second end of the article, and the airflow path extends within the article between the first and second ends. An airflow path extending in the longitudinal direction may be defined within the article between the first and second ends, and the airflow path extends between the first and second ends and is defined within the peripheral wall that surrounds the airflow path circumferentially.

[0088] The article may be any article described herein. For example, the outer surface of the article may be defined by a peripheral wall which is deformable in an axial cross-section and configured to expand from a contracted first state to an expanded second state, in which the peripheral wall surrounds a hollow tubular cavity. Thus, the article may be shipped and stored in a contracted or flattened state and then expanded during or before use. The presence of at least one flap as described herein may help the article maintain the second expanded state by effectively locking the article in the expanded state when the flap is folded. In the contracted first state, there is no hollow tubular cavity, but there is one in the expanded state. The hollow tubular cavity may provide an airflow path through the article.

[0089] In the first contracted state, the opposing inward-facing surfaces of the peripheral walls may be in surface contact with each other. Therefore, in this contracted state, there is no airflow path defined through the article. The airflow path may be opened when the article is operated to its second expanded state.

[0090] The cross-sectional area of ​​the article in the expanded state may be any suitable cross-section, for example, elliptical or oval. In the expanded second state, the peripheral wall of the aerosol-generating article is preferably lenticular in its axial cross-section. The peripheral wall of the aerosol-generating article may be configured to define a band, and the peripheral wall is lenticular in its axial cross-section.

[0091] Preferably, at least one flap is configured to fold to a position in which at least one flap acts to prevent the surrounding wall from contracting from its expanded state to its contracted state. Preferably, at least one flap is permeable to air, for example, by defining at least one through-hole, thereby defining an airflow path through at least one flap.

[0092] A tenth aspect of the present disclosure provides a package comprising a plurality of aerosol-generating articles and a container for receiving the plurality of aerosol-generating articles, the aerosol-generating articles being, for example, as described in any of the preceding paragraphs. Each aerosol-generating article may extend longitudinally between a first and second opposing end of each aerosol-generating article, and the peripheral wall of the aerosol-generating article is configured to define a flat shape that is contracted in the axial cross-section.

[0093] The aerosol-generating article received in the container may be as described in the second aspect of this disclosure, or it may correspond to the contracted first state of the third aspect of this disclosure.

[0094] Preferably, for one or more of the multiple aerosol-generating articles, the opposing inward-facing surfaces of the peripheral walls of each aerosol-generating article are in surface contact with each other. In this way, the aerosol-generating articles may be provided with a cross-sectional profile of minimum thickness, thereby facilitating efficient packaging of the articles in the container.

[0095] For one or more of the multiple aerosol-generating articles, the opposing outward-facing surfaces of the peripheral walls of each aerosol-generating article may be aligned parallel to each other.

[0096] For one or more of the multiple aerosol-generating articles, the opposing outward-facing surfaces of the peripheral walls of each aerosol-generating article may generally be flat.

[0097] It is preferable that adjacent aerosol-generating articles among multiple aerosol-generating articles be positioned side-by-side within the container, touching ends within the container, or in a combination thereof.

[0098] Advantageously, at least one lid is attached to the container and is configured to move from an open position to a closed position, in which case the lid covers multiple aerosol-generating articles received inside the container.

[0099] An eleventh aspect of the present disclosure provides a device comprising a cavity configured to form a funnel-shaped aerosol generating article, thereby expanding the aerosol generating article from a flat cross-sectional shape to a lenticular cross-sectional shape along at least part or all of the length of the aerosol generating article. For example, the aerosol generating article may be one of those described in any of the preceding paragraphs.

[0100] In a twelfth aspect of the present disclosure, an apparatus comprising a cavity and a pin is provided. The pin may be located within the cavity. The pin may be inserted into an aerosol generating article that is funnel-shaped along the cavity, thereby expanding the aerosol generating article from a flat cross-sectional shape to a lenticular cross-sectional shape along at least part or all of its length. For example, the apparatus may be as described in any of the preceding paragraphs, and / or the aerosol generating article may be as described in any of the preceding paragraphs.

[0101] Further embodiments of the present disclosure provide a system comprising the apparatus described in either of the two preceding paragraphs. The system may further comprise an aerosol-generating article having a first state in which the article has a flat cross-sectional shape, and a second state in which the article has a lenticular cross-sectional shape.

[0102] As used herein, the term "aerosol-generating article" refers to an article comprising an aerosol-forming substrate having the ability to release volatile compounds capable of forming aerosols. Aerosol-generating articles may be disposable.

[0103] As used herein, the term "aerosol-forming substrate" refers to a substrate consisting of, or containing, an aerosol-forming material having the ability to release volatile compounds upon heating in order to generate an aerosol.

[0104] The aerosol-forming substrate is preferably a solid aerosol-forming substrate. However, the aerosol-forming substrate may contain both solid and liquid components. Alternatively, the aerosol-forming substrate may be a liquid aerosol-forming substrate.

[0105] The aerosol-forming substrate preferably contains nicotine. More preferably, the aerosol-forming substrate contains tobacco. Alternatively, or additionally, the aerosol-forming substrate may contain a non-tobacco-containing aerosol-forming material.

[0106] When the aerosol-forming substrate is a solid aerosol-forming substrate, the solid aerosol-forming substrate may contain one or more of the following: herb leaves, tobacco leaves, tobacco stems, puffed tobacco, and homogenized tobacco, for example, one or more of the following: powder, granules, pellets, fragments, twisted yarn, splinters, or sheets.

[0107] Optionally, the solid aerosol-forming substrate may contain tobacco or non-tobacco volatile flavor compounds, which are released upon heating of the solid aerosol-forming substrate. The solid aerosol-forming substrate may also contain, for example, one or more capsules containing additional tobacco volatile flavor compounds or non-tobacco volatile flavor compounds, which may melt during heating of the solid aerosol-forming substrate.

[0108] Optionally, the solid aerosol-forming substrate may be provided on or embedded within a thermally stable carrier. The carrier may take the form of a powder, granules, pellets, fragments, yarns, strips, or sheets. The solid aerosol-forming substrate may be deposited on the surface of the carrier, for example, in the form of a sheet, foam, gel, or slurry. The solid aerosol-forming substrate may be deposited over the entire surface of the carrier, or alternatively, in a pattern to provide non-uniform flavor delivery during use.

[0109] In preferred embodiments, the aerosol-forming substrate comprises homogenized tobacco material. As used herein, the term “homogenized tobacco material” refers to material formed by agglomerating particulate tobacco.

[0110] The aerosol-forming substrate preferably comprises an aggregate of homogenized tobacco material sheets. As used herein, the term “sheet” refers to a layered element having a width and length substantially greater than its thickness. As used herein, the term “aggregated” is used to describe a sheet that is wrapped, folded, or otherwise compressed or clamped substantially transversely to the longitudinal axis of the aerosol-generating article. Preferably, the aerosol-forming substrate comprises an aerosol-forming compound. As used herein, the term “aerosol-forming compound” is used to describe any suitable known compound or mixture of compounds that facilitates aerosol formation during use and is substantially resistant to thermal decomposition at the operating temperature of the aerosol-generating article.

[0111] Suitable aerosol-forming materials are known in the art and include, but are not limited to, polyhydric alcohols (such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerin), esters of polyhydric alcohols (such as glycerol monoacetate, diacetate, or triacetate), and aliphatic esters of monocarboxylic acids, dicarboxylic acids, or polycarboxylic acids (such as dimethyl dodecanediate and dimethyl tetradecanediate). Preferred aerosol-forming materials are polyhydric alcohols or mixtures thereof (such as propylene glycol, triethylene glycol, 1,3-butanediol, and most preferably glycerin).

[0112] The aerosol-forming substrate may comprise a single aerosol-forming body. Alternatively, the aerosol-forming substrate may comprise a combination of two or more aerosol-forming bodies.

[0113] As used herein, the term “mouthpiece” refers to a portion of an aerosol generating article that is placed in the user’s mouth for direct inhalation of an aerosol. The second end of the aerosol generating article referred to herein preferably defines the “mouthpiece” or mouth-side end.

[0114] As used herein, the term "inhalation" means the act of a user inhaling an aerosol into their body through their mouth or nose.

[0115] When used herein, the terms “upstream” and “front,” and “downstream” and “rear” are used to describe the relative positions of components or parts of components of an aerosol-generating article with respect to the direction through which air flows during use of the aerosol-generating article. The aerosol-generating article described in this invention may have a proximal end through which an aerosol exits the article during use. The proximal end of an aerosol-generating article may also be called the mouth end or downstream end. The mouth end is downstream of the distal end of the article. The distal end of an aerosol-generating article may also be called the upstream end. Components or parts of components of an aerosol-generating article may be described as being upstream or downstream of each other based on their relative positions between the proximal end and the distal end of the aerosol-generating article. The front of a component or part of a component of an aerosol-generating article is the part closest to the upstream end of the aerosol-generating article. The rear of a component or part of a component of an aerosol-generating article is the part closest to the downstream end of the aerosol-generating article.

[0116] Naturally, any one feature of the aspects of this disclosure may be combined with any one or more features of the other aspects of this disclosure. [Brief explanation of the drawing]

[0117] [Figure 1] Figure 1 is a schematic perspective view of an aerosol-generating article according to the first embodiment. [Figure 2] Figure 2 is a schematic diagram of the aerosol-generating article shown in Figure 1, viewed downstream between the first and second opposing ends of the article, along the longitudinal axis of the aerosol-generating article. [Figure 3A] Figure 3A is a schematic diagram of the peripheral wall segments of three different embodiments of the aerosol generating article shown in Figures 1 and 2. [Figure 3B] Figure 3B is a schematic diagram of the peripheral wall segments of three different embodiments of the aerosol generating article shown in Figures 1 and 2. [Figure 3C] Figure 3C is a schematic diagram of the peripheral wall segments of three different embodiments of the aerosol generating article shown in Figures 1 and 2. [Figure 4A] Figure 4A is a schematic axial cross-sectional view of the peripheral wall of one embodiment of an aerosol-generating article in two different states. [Figure 4B] Figure 4B is a schematic axial cross-sectional view of the peripheral wall of one embodiment of an aerosol-generating article in two different states. [Figure 5A] Figure 5A is a schematic axial cross-sectional view of the peripheral wall of another embodiment of an aerosol-generating article in two different states. [Figure 5B] Figure 5B is a schematic axial cross-sectional view of the peripheral wall of another embodiment of an aerosol-generating article in two different states. [Figure 6] Figure 6 shows a schematic perspective view of a package having a container for receiving multiple aerosol-generating articles, the aerosol-generating articles being in a contracted first state, which generally corresponds to that shown in Figure 5A. [Figure 7A] Figure 7A is a schematic axial cross-sectional view of the peripheral wall of three different embodiments of the aerosol generating article, all three embodiments employ a single sheet of support substrate folded around a fold such that the first part of the support substrate sheet rests on the second part of the support substrate sheet. The embodiments differ from one another in the configuration of the aerosol-forming substrate sheet resting on the support substrate sheet. [Figure 7B]Figure 7B is a schematic axial cross-sectional view of the peripheral wall of three different embodiments of the aerosol generating article, all three embodiments employ a single sheet of support substrate folded around a fold such that the first part of the support substrate sheet rests on the second part of the support substrate sheet. The embodiments differ from one another in the configuration of the aerosol-forming substrate sheet resting on the support substrate sheet. [Figure 7C] Figure 7C is a schematic axial cross-sectional view of the peripheral wall of three different embodiments of the aerosol generating article, all three embodiments employ a single sheet of support substrate folded around a fold such that the first part of the support substrate sheet rests on the second part of the support substrate sheet. The embodiments differ from one another in the configuration of the aerosol-forming substrate sheet resting on the support substrate sheet. [Figure 8A] Figure 8A is a schematic axial cross-sectional view of the peripheral wall of three different embodiments of the aerosol generating article, all three embodiments employing separate first and second sheets of a support base arranged opposite to each other such that the laterally opposing edges of the first and second sheets of the support base align to define the laterally opposing edges of the peripheral wall. The embodiments differ from each other in the configuration of the aerosol-forming base sheets on the first and second sheets of the support base. [Figure 8B] Figure 8B is a schematic axial cross-sectional view of the peripheral wall of three different embodiments of the aerosol generating article, all three embodiments employing separate first and second sheets of a support base arranged opposite to each other such that the laterally opposing edges of the first and second sheets of the support base align to define the laterally opposing edges of the peripheral wall. The embodiments differ from each other in the configuration of the aerosol-forming substrate sheets on the first and second sheets of the support base. [Figure 8C]Figure 8C is a schematic axial cross-sectional view of the peripheral wall of three different embodiments of the aerosol generating article, all three embodiments employing separate first and second sheets of a support base arranged opposite each other such that the laterally opposing edges of the first and second sheets of the support base align to define the laterally opposing edges of the peripheral wall. The embodiments differ from each other in the configuration of the aerosol-forming substrate sheets on the first and second sheets of the support base. [Figure 9A] Figure 9A is a schematic axial cross-sectional view of the peripheral wall of three different embodiments of the aerosol generating article, all three embodiments employ a single sheet of aerosol-forming substrate folded around a fold such that the first portion of the aerosol-forming substrate sheet rests on the second portion of the aerosol-forming substrate sheet. The embodiments differ from one another in the configuration of the support substrate sheet resting on the aerosol-forming substrate sheet. [Figure 9B] Figure 9B is a schematic axial cross-sectional view of the peripheral wall of three different embodiments of the aerosol generating article, all three embodiments employ a single sheet of aerosol-forming substrate folded around a fold such that the first portion of the aerosol-forming substrate sheet rests on the second portion of the aerosol-forming substrate sheet. The embodiments differ from one another in the configuration of the support substrate sheet resting on the aerosol-forming substrate sheet. [Figure 9C] Figure 9C is a schematic axial cross-sectional view of the peripheral wall of three different embodiments of the aerosol generating article, all of which employ a single sheet of aerosol-forming substrate folded around a fold such that the first portion of the aerosol-forming substrate sheet rests on the second portion of the aerosol-forming substrate sheet. The embodiments differ from one another in the configuration of the support substrate sheet resting on the aerosol-forming substrate sheet. [Figure 10A]Figure 10A is a schematic axial cross-sectional view of the peripheral wall of three different embodiments of the aerosol generating article, all three embodiments employing separate first and second sheets of aerosol-forming substrate arranged opposite to each other such that the laterally opposing edges of the first and second sheets of the aerosol-forming substrate align to define the laterally opposing edges of the peripheral wall. The embodiments differ from each other in the configuration of the support substrate sheets that rest on the first and second sheets of the aerosol-forming substrate. [Figure 10B] Figure 10B is a schematic axial cross-sectional view of the peripheral wall of three different embodiments of the aerosol generating article, all three embodiments employing separate first and second sheets of aerosol-forming substrate arranged opposite to each other such that the laterally opposing edges of the first and second sheets of the aerosol-forming substrate align to define the laterally opposing edges of the peripheral wall. The embodiments differ from each other in the configuration of the support substrate sheets that rest on the first and second sheets of the aerosol-forming substrate. [Figure 10C] Figure 10C is a schematic axial cross-sectional view of the peripheral wall of three different embodiments of the aerosol generating article, all three embodiments employing separate first and second sheets of aerosol-forming substrate arranged opposite to each other such that the laterally opposing edges of the first and second sheets of the aerosol-forming substrate align to define the laterally opposing edges of the peripheral wall. The embodiments differ from each other in the configuration of the support substrate sheets that rest on the first and second sheets of the aerosol-forming substrate. [Figure 11] Figure 11 is a schematic axial cross-sectional view of the peripheral wall of one embodiment of an aerosol generating article, employing a single sheet of aerosol-forming substrate folded around a fold such that the first part of the aerosol-forming substrate sheet is on top of the second part of the aerosol-forming substrate sheet, but no separate sheet of support substrate material is added. [Figure 12]Figure 12 is a schematic axial cross-sectional view of the peripheral wall of one embodiment of an aerosol generating article. It employs separate first and second sheets of aerosol-forming substrate arranged opposite to each other, such that the laterally opposing edges of the first and second sheets of aerosol-forming substrate align and define the laterally opposing edges of the peripheral wall. However, no separate sheet of support substrate material is added. [Figure 13A] Figure 13A is a schematic perspective view of a further embodiment of an aerosol generating article, in which a portion of the peripheral wall of the aerosol generating article is configured to be air permeable and is surrounded by a sleeve of an aerosol forming substrate. [Figure 13B] Figure 13B is a schematic perspective view of a further embodiment of an aerosol generating article, in which a portion of the peripheral wall of the aerosol generating article is configured to be air permeable and is surrounded by a sleeve of an aerosol forming substrate. [Figure 14] Figure 14 is a schematic top view of an aerosol-generating article according to a specific embodiment of the present invention, arranged in a contracted or flattened state. [Figure 15] Figure 15 shows the side projection of the aerosol-generating article from Figure 14 in a contracted state. [Figure 16] Figure 16 is a bottom plan view of the aerosol generating article shown in Figure 14 in a contracted state. [Figure 17] Figure 17 shows the mouth-side protrusion of the aerosol-generating article from Figure 14 in a contracted state. [Figure 18] Figure 18 shows the distal end projection of the aerosol-generating article from Figure 14 in a contracted state. [Figure 19] Figure 19 is a schematic top view of the aerosol-generating article of Figure 14, showing the transition from a contracted or flat state to an expanded or extended state. [Figure 20] Figure 20 is a schematic top view of the aerosol generating article of Figure 14, either expanded or in an expanded state. [Figure 21] Figure 21 shows the side projection of the aerosol-generating article from Figure 14 in its expanded state. [Figure 22]Figure 22 is a bottom plan view of the aerosol generating article shown in Figure 14 in its expanded state. [Figure 23] Figure 23 shows the mouth-side protrusion of the aerosol generating article from Figure 14 in its expanded state. [Figure 24] Figure 24 shows the distal end projection of the aerosol generating article from Figure 14 in its expanded state. [Figure 25] Figure 25 is a schematic top view of an aerosol-generating article according to a further specific embodiment of the present invention, arranged in an expanded or extended state. [Figure 26] Figure 26 shows the side projection of the aerosol-generating article from Figure 25 in its expanded state. [Figure 27] Figure 27 shows the mouth-side protrusion of the aerosol generating article from Figure 25 in its expanded state. [Figure 28] Figure 28 shows the distal end projection of the aerosol generating article from Figure 25 in its expanded state. [Figure 29] Figure 29 is a plan view showing a material sheet for use in forming the peripheral wall of an aerosol generating article, such as the aerosol generating articles shown in Figures 14-28. [Modes for carrying out the invention]

[0118] The present invention is defined in the claims. However, a non-exclusive list of non-limiting embodiments is provided below. Any one or more features in these embodiments may be combined with any one or more features in other embodiments, other forms, or other aspects described herein.

[0119] Example 1: An aerosol generating article extending in the longitudinal direction between opposing first and second ends, wherein the aerosol generating article has a peripheral wall, and the peripheral wall is lens-shaped in an axial cross-section. Example 2: The aerosol generating article according to Embodiment 1, wherein the peripheral wall comprises opposing first and second convex portions, and the opposing ends of the first convex portion coincide with the corresponding opposing ends of the second convex portion to define a pair of laterally opposing edges of the peripheral wall. Example 3: The aerosol generating article according to Example 2, wherein at each of the two laterally opposing edges of the peripheral wall, the outer surface of the peripheral wall has a radius of curvature of less than 2 millimeters, or less than 1 millimeter, or less than 0.5 millimeters, or less than 0.25 millimeters. Example 4: An aerosol-generating article according to either one of Example 2 or 3, wherein the peripheral wall includes a pair of folds, and the pair of folds define a pair of laterally opposing edges of the peripheral wall. Example 5: An aerosol generating article according to any one of Examples 2 to 4, wherein, at each position of a pair of laterally opposing edges of the peripheral wall, the acute angle between the first tangent to the outer surface of the first convex portion and the second tangent to the outer surface of the second convex portion is within the range of 15 to 110 degrees, or 15 to 90 degrees, or 15 to 75 degrees, or 15 to 65 degrees, or 15 to 55 degrees, or 15 to 45 degrees, or 15 to 35 degrees, or 15 to 25 degrees. Example 6: An aerosol generating article according to any one of Examples 2 to 5, wherein the radius of curvature of the inner surfaces of the first and second convex portions, located at an intermediate position between a pair of laterally opposing edges of the peripheral wall, is 100 mm to 500 mm. Example 7: An aerosol generating article according to any one of Examples 1 to 6, wherein the aerosol generating article has a width of 20 mm or less. Example 8: The aerosol generating article according to Example 7, wherein the width of the aerosol generating article is in the range of 14 mm to 20 mm. Example 9: An aerosol generating article according to any one of Examples 1 to 8, wherein the aerosol generating article has a thickness of 8 mm or less. Example 10: The aerosol-generating article according to Example 9, wherein the thickness of the aerosol-generating article is in the range of 3 mm to 8 mm, or 3 mm to 6 mm, or 3 mm to 5 mm. Example 11: The aerosol-generating article according to any one of Examples 1 to 10, further comprising at least one flap located at one of a first end and a second end, wherein the at least one flap is configured to fold so as to overlap at least a portion of the end in which the flap is located. Example 12: The aerosol-generating article according to Example 11, wherein at least one flap is configured to be folded by the user. Example 13: The aerosol-generating article according to either one of Embodiments 11 or 12, wherein at least one flap is configured to fold so as to cover, for example, an opening and / or extend into the opening, covering at least a portion of an opening defined at the end where the flap is located. Example 14: An aerosol-generating article according to any one of Examples 11 to 13, wherein the flap is connected to the article at a fold, for example, a score line. Example 15: The aerosol-generating article according to Example 14, wherein the flap is configured to fold along a crease such that the flap overlaps with at least a portion of the opening. Example 16: The aerosol generating article according to Example 14 or 15, wherein the flap is configured to fold along a crease such that the edge of the flap is located within the opening, for example, so that the edge of the flap is in contact with the inner wall of the aerosol generating article, for example, the inner wall of a chamber accessed through the opening. Example 17: The aerosol generating article according to Example 16, wherein the inner wall of the aerosol generating article is part of the surrounding wall. Example 18: An aerosol generating article having a peripheral wall, the peripheral wall defining a flat shape that is contracted in an axial cross-section, and extending in the longitudinal direction between opposing first and second ends, for example, the aerosol generating article according to any one of Examples 1 to 17. Example 19: The aerosol-generating article according to Example 18, wherein the opposing inward-facing surfaces of the surrounding walls are in surface contact with each other. Example 20: An aerosol-generating article according to either Example 18 or 19, wherein the opposing outward-facing surfaces of the surrounding walls are parallel to each other. Example 21: An aerosol-generating article according to any one of Examples 18 to 20, wherein the opposing outward-facing surfaces of the surrounding walls are generally flat. Example 22: An aerosol generating article according to any one of Examples 18 to 21, wherein the aerosol generating article has a thickness of 5 mm or less. Example 23: The aerosol-generating article according to Example 22, wherein the thickness of the aerosol-generating article is in the range of 0.5 mm to 5 mm, or 0.5 mm to 3 mm, or 0.5 mm to 2 mm, or 0.5 mm to 1.5 mm. Example 24: An aerosol generating article extending longitudinally between opposing first and second ends, for example, the aerosol generating article according to any one of Examples 1 to 23, wherein the aerosol generating article comprises a peripheral wall, the peripheral wall is configured to be deformable, causing a contraction in the width of the aerosol generating article and a corresponding expansion in the thickness of the aerosol generating article, thereby transitioning the aerosol generating article from a contracted first state to an expanded second state, in which the area enclosed by the peripheral wall is larger than that in the contracted first state. Example 25: The aerosol-generating article according to Example 24, wherein in the first contracted state, the opposing inward-facing surfaces of the peripheral walls are in surface contact with each other. Example 26: The aerosol-generating article according to either Example 24 or 25, wherein in the first contracted state, the opposing outward-facing surfaces of the peripheral walls are parallel to each other. Example 27: In the first contracted state, the aerosol-generating article according to any one of Examples 24 to 26, wherein the opposing outward-facing surfaces of the peripheral walls are generally flat. Example 28: In the expanded second state, the aerosol generating article according to any one of Examples 24 to 27, wherein the peripheral wall of the aerosol generating article is lenticular in its axial cross-section. Example 29: An aerosol generating article according to any one of Examples 24 to 28, wherein the peripheral wall includes opposing first and second portions, the opposing ends of the first portion coincide with the corresponding opposing ends of the second portion to define a pair of laterally opposing edges of the peripheral wall, and the deformation of the pair of laterally opposing edges toward each other causes the peripheral wall to be adapted to introduce or increase the separation between the opposing first and second portions of the peripheral wall at the position between the pair of laterally opposing edges, thereby causing the aerosol generating article to transition between a contracted first state and an expanded second state. Example 30: The aerosol generating article according to any one of Examples 1 to 29, wherein the aerosol generating article includes an aerosol forming substrate, which preferably forms at least a portion of the peripheral wall. Example 31: The aerosol generating article according to Example 30, wherein the aerosol-forming substrate is configured to generate an inhalable aerosol when heated. Example 32: An aerosol generating article according to either Example 30 or 31, wherein the surrounding wall includes an aerosol-forming substrate and a support substrate. Example 33: The aerosol-forming substrate according to Example 32, wherein the surrounding wall comprises at least one sheet of aerosol-forming substrate and at least one sheet of support substrate. Example 34: The aerosol-forming article according to Example 33, wherein the peripheral wall defines a laminated structure formed from both at least one sheet of aerosol-forming substrate and at least one sheet of support substrate. Example 35: An aerosol-forming substrate according to any one of Examples 1 to 34, wherein the surrounding wall includes a band of aerosol-forming substrate. Example 36: An aerosol generating article according to any one of Examples 1 to 35, wherein the surrounding wall includes a support base band. Example 37: An aerosol generating article according to a combination of Examples 35 and 36, wherein a band of aerosol-forming substrate radially surrounds or encloses a band of support substrate. Example 38: An aerosol generating article according to any one of Examples 32 to 37, wherein the support base is cardboard. Example 39: An aerosol generating article comprising a peripheral wall, the peripheral wall comprising at least one support base sheet, a fold defined within at least one support base sheet defining a folded support base sheet, and an aerosol generating article extending between opposing first and second ends, wherein the first part of the folded support base sheet is on top of a second part of the folded support base sheet, defining a closed path corresponding to the peripheral wall, for example, the aerosol generating article according to any one of Examples 1 to 38. Example 40: The aerosol generating article according to Example 39, wherein a first portion of the folded support base sheet extends over a first half of the circumferential length of the peripheral wall, and a second portion of the folded support base sheet extends over a second half of the circumferential length of the peripheral wall. Example 41: The surrounding wall further comprises at least one sheet of aerosol-forming substrate, and at least one sheet of aerosol-forming substrate, An outer arrangement of one or more sheets of an aerosol-forming substrate, wherein the outer arrangement of one or more sheets of the aerosol-forming substrate is positioned to cover (preferably surface-contact) both outward-facing surfaces of the first and second portions of the folded support substrate sheet, An aerosol generating article according to either Example 39 or 40, comprising one or both of the internal arrangements of one or more sheets of the aerosol-forming substrate, wherein the internal arrangements of one or more sheets of the aerosol-forming substrate are positioned to cover (preferably in surface contact with) the inward-facing surfaces of both the first and second portions of the folded support substrate sheets. Example 42: The aerosol generating article according to Example 41, wherein the outer arrangement comprises a common sheet of aerosol-forming substrate arranged to cover (preferably in surface contact with) both outward-facing surfaces of the first and second portions of the folded support substrate sheet. Example 43: The aerosol generating article according to either Example 41 or 42, wherein the internal arrangement comprises a common sheet of aerosol-forming substrate arranged to cover (preferably in surface contact with) both the inward-facing surfaces of the first and second portions of the folded support substrate sheet. Example 44: The aerosol generating article according to Example 41, wherein the outer arrangement comprises a first outer sheet of an aerosol-forming substrate arranged to cover (preferably in surface contact with) the outward-facing surface of a first portion of the sheet of a folded support base, and a second outer sheet of an aerosol-forming substrate arranged to cover (preferably in surface contact with) the outward-facing surface of a second portion of the sheet of a folded support base. Example 45: The aerosol generating article according to either Example 41 or 44, wherein the internal arrangement comprises a first inner sheet of an aerosol-forming substrate arranged to cover (preferably in surface contact with) the inward-facing surface of a first portion of the sheet of a folded support substrate, and a second inner sheet of an aerosol-forming substrate arranged to cover (preferably in surface contact with) the inward-facing surface of a second portion of the sheet of a folded support substrate. Example 46: An aerosol generating article comprising a peripheral wall, the peripheral wall comprising at least one support substrate sheet, the at least one support substrate sheet comprising a first support substrate sheet and a second support substrate sheet arranged opposite to each other, the laterally opposing edges of the first and second support substrate sheets align with each other to define a laterally opposing edge of the peripheral wall, and the first support substrate sheet and the second support substrate sheet thereby define a closed path corresponding to the peripheral wall, an aerosol generating article extending between opposing first and second ends, for example, the aerosol generating article according to any one of Examples 1 to 45. Example 47: The aerosol generating article according to Example 46, wherein the first sheet of the support base extends over the first half of the circumference of the peripheral wall, and the second sheet of the support base extends over the second half of the circumference of the peripheral wall. Example 48: The surrounding wall further comprises at least one sheet of aerosol-forming substrate, and at least one sheet of aerosol-forming substrate, An outer arrangement of one or more sheets of an aerosol-forming substrate, wherein the outer arrangement of one or more sheets of the aerosol-forming substrate is positioned to cover (preferably be in surface contact with) the outward-facing surfaces of both the first sheet and the second sheet of the support substrate, An aerosol generating article according to either Example 46 or 47, comprising one or both of the following: an internal arrangement of one or more sheets of an aerosol-forming substrate, wherein the internal arrangement of one or more sheets of the aerosol-forming substrate is positioned to cover (preferably be in surface contact with) the inward-facing surfaces of both the first sheet and the second sheet of the support substrate. Example 49: The aerosol generating article according to Example 48, wherein the outer arrangement comprises a common sheet of an aerosol-forming substrate arranged to cover (preferably in surface contact with) the outward-facing surfaces of both the first sheet of the support substrate and the second sheet of the support substrate. Example 50: The aerosol generating article according to either Example 48 or 49, wherein the internal arrangement comprises a common sheet of aerosol-forming substrate arranged to cover (preferably in surface contact with) the inward-facing surfaces of both the first sheet of the support substrate and the second sheet of the support substrate. Example 51: The aerosol generating article according to Example 48, wherein the outer arrangement comprises a first outer sheet of an aerosol-forming substrate arranged to cover (preferably in surface contact with) the outward-facing surface of a first sheet of a support substrate, and a second outer sheet of an aerosol-forming substrate arranged to cover (preferably in surface contact with) the outward-facing surface of a second sheet of a support substrate. Example 52: An aerosol generating article according to either Example 48 or 51, wherein the internal arrangement comprises a first inner sheet of an aerosol-forming substrate arranged to cover (preferably in surface contact with) the inward-facing surface of a first sheet of a support substrate, and a second inner sheet of an aerosol-forming substrate arranged to cover (preferably in surface contact with) the inward-facing surface of a second sheet of a support substrate. Example 53: An aerosol generating article comprising a peripheral wall and at least one sheet of an aerosol forming substrate, wherein a fold is defined within at least one sheet of the aerosol forming substrate so as to define a folded sheet of the aerosol forming substrate, and the aerosol generating article extends between opposing first and second ends, with the first portion of the folded sheet of the aerosol forming substrate being on top of a second portion of the folded sheet of the aerosol forming substrate, thereby defining a closed path corresponding to the peripheral wall, for example, the aerosol generating article according to any one of Examples 1 to 52. Example 54: The aerosol generating article according to Example 53, wherein a first portion of the folded aerosol-forming substrate sheet extends over a first half of the circumferential length of the peripheral wall, and a second portion of the folded aerosol-forming substrate sheet extends over a second half of the circumferential length of the peripheral wall. Example 55: The surrounding wall further comprises at least one support base sheet, and at least one support base sheet, An outer arrangement of one or more sheets of a support base, wherein the outer arrangement of one or more sheets of the support base is positioned to cover (preferably surface-contact) both outward-facing surfaces of the first and second portions of the folded aerosol-forming base sheet, An aerosol generating article according to either Example 53 or 54, comprising one or both of the following: an internal arrangement of one or more sheets of a support base, wherein the internal arrangement of one or more sheets of the support base is positioned to cover (preferably be in surface contact with) the inward-facing surfaces of both the first and second portions of the folded aerosol-forming base sheet. Example 56: The aerosol generating article according to Example 55, wherein the outer arrangement comprises a common sheet of a support substrate arranged to cover (preferably in surface contact with) the outward-facing surfaces of both the first and second portions of the folded aerosol-forming substrate sheet. Example 57: The aerosol generating article according to either Example 55 or 56, wherein the internal arrangement comprises a common sheet of a support substrate arranged to cover (preferably in surface contact with) the inward-facing surfaces of both the first and second portions of the folded aerosol-forming substrate sheet. Example 58: The aerosol generating article according to Example 55, wherein the outer arrangement comprises a first outer sheet of a support base disposed to cover (preferably in surface contact with) the outward-facing surface of a first portion of the folded aerosol-forming substrate sheet, and a second outer sheet of the support base disposed to cover (preferably in surface contact with) the outward-facing surface of a second portion of the folded aerosol-forming substrate sheet. Example 59: The aerosol generating article according to either Example 55 or 58, wherein the internal arrangement comprises a first inner sheet of a support base disposed to cover (preferably in surface contact with) the inward-facing surface of a first portion of the folded aerosol-forming substrate sheet, and a second inner sheet of the support base disposed to cover (preferably in surface contact with) the inward-facing surface of a second portion of the folded aerosol-forming substrate sheet. Example 60: An aerosol generating article comprising a peripheral wall, the peripheral wall comprising at least one sheet of an aerosol forming substrate, the at least one sheet of the aerosol forming substrate comprising a first sheet of the aerosol forming substrate and a second sheet of the aerosol forming substrate arranged opposite to each other, the laterally opposing edges of the first and second sheets of the aerosol forming substrate align with each other to define the laterally opposing edges of the peripheral wall, the first and second sheets of the aerosol forming substrate thereby defining a closed path corresponding to the peripheral wall, an aerosol generating article extending between opposing first and second ends, for example, the aerosol generating article according to any one of Examples 1 to 59. Example 61: The aerosol generating article according to Example 60, wherein a first sheet of aerosol-forming substrate extends over a first half of the circumferential length of the peripheral wall, and a second sheet of aerosol-forming substrate extends over a second half of the circumferential length of the peripheral wall. Example 62: The surrounding wall further comprises at least one support base sheet, and at least one support base sheet, An outer arrangement of one or more sheets of a support base, wherein the outer arrangement of one or more sheets of the support base is positioned to cover (preferably be in surface contact with) the outward-facing surfaces of both the first sheet of the aerosol-forming base and the second sheet of the aerosol-forming base, An aerosol generating article according to either Example 60 or 61, comprising one or both of the following: an internal arrangement of one or more sheets of a support base, wherein the internal arrangement of one or more sheets of the support base is positioned to cover (preferably be in surface contact with) the inward-facing surfaces of both the first sheet of the aerosol-forming base and the second sheet of the aerosol-forming base. Example 63: The aerosol generating article according to Example 62, wherein the outer arrangement comprises a common sheet of a support substrate arranged to cover (preferably in surface contact with) the outward-facing surfaces of both the first and second sheets of the aerosol-forming substrate. Example 64: The aerosol generating article according to either Example 62 or 63, wherein the internal arrangement comprises a common sheet of a support substrate arranged to cover (preferably in surface contact with) the inward-facing surfaces of both the first and second sheets of the aerosol-forming substrate. Example 65: The aerosol generating article according to Example 62, wherein the outer arrangement comprises a first outer sheet of a support base disposed to cover (preferably in surface contact with) the outward surface of the first sheet of the aerosol forming substrate, and a second outer sheet of the support base disposed to cover (preferably in surface contact with) the outward surface of the second sheet of the aerosol forming substrate. Example 66: The aerosol generating article according to either Example 62 or 65, wherein the internal arrangement comprises a first inner sheet of a support base disposed to cover (preferably in surface contact with) the inward surface of a first sheet of an aerosol forming substrate, and a second inner sheet of a support base disposed to cover (preferably in surface contact with) the inward surface of a second sheet of an aerosol forming substrate. Example 67: An aerosol generating article according to any one of Examples 1 to 66, wherein the peripheral wall includes or consists of a strip of aerosol-forming substrate, and the strip of aerosol-forming substrate is configured to provide all or at least most of the bending rigidity of the peripheral wall. Example 68: The aerosol generating article according to Example 67, wherein the band of aerosol-forming substrate comprises at least one sheet of aerosol-forming substrate. Example 69: The aerosol generating article according to Example 68, wherein a fold is defined in at least one sheet of the aerosol-forming substrate, defining a folded sheet of the aerosol-forming substrate, and the sheet is folded around the fold such that a first portion of the folded sheet of the aerosol-forming substrate lies on a second portion of the folded sheet of the aerosol-forming substrate, defining a closed path corresponding to a peripheral wall. Example 70: The aerosol generating article according to Example 69, wherein a first portion of the folded aerosol-forming substrate sheet extends over a first half of the circumferential length of the peripheral wall, and a second portion of the folded aerosol-forming substrate sheet extends over a second half of the circumferential length of the peripheral wall. Example 71: An aerosol generating article according to any one of Examples 1 to 70, wherein the surrounding wall is provided with a wrapper, and the wrapper defines the outer surface of the aerosol generating article. Example 72: The aerosol-generating article according to Example 71, wherein the wrapper contains or consists of cigarette paper. Example 73: An aerosol generating article comprising a peripheral wall, the peripheral wall comprising a support base and at least a portion of the axial length of the peripheral wall configured to be permeable to air, and the arrangement of one or more sheets of the aerosol forming base being positioned to radially surround the air-permeable portion of the axial length of the peripheral wall, an aerosol generating article extending in the longitudinal direction between opposing first and second ends, for example, the aerosol generating article according to any one of Examples 1 to 72. Example 74: The aerosol generating article according to Example 73, wherein the arrangement of one or more sheets of the aerosol-forming substrate is configured to form a sleeve that radially surrounds an air-permeable portion of the peripheral wall in the axial direction. Example 75: The aerosol generating article according to either Example 73 or 74, wherein one or more sheets of the aerosol-forming substrate are positioned closer to the first end of the aerosol generating article than to the second end of the aerosol generating article, and it is preferable that the second end of the article defines the mouth end of the article. Example 76: An aerosol generating article according to any one of Examples 73 to 75, wherein the air permeable portion of the peripheral wall along its axial length includes a plurality of openings. Example 77: An aerosol generating article according to any one of Examples 73 to 76, wherein an air-permeable portion of the peripheral wall along its axial length is made of an air-permeable material. Example 78: The aerosol generating article according to Example 77, wherein the air-permeable material is a porous material. Example 79: An aerosol generating article according to any one of Examples 1 to 78, wherein the aerosol generating article has a length of 100 mm or less, or 90 mm or less. Example 80: The aerosol generating article according to Example 79, wherein the length of the aerosol generating article is within the range of 20 mm to 100 mm, or 25 mm to 100 mm, or 30 mm to 100 mm, or 35 mm to 100 mm, or 40 mm to 100 mm. Example 81: An aerosol-generating article extending longitudinally between a first end and a second end, for example, the aerosol-generating article according to any one of Examples 1 to 80, wherein at least one flap is located at one of a first end and a second end, and at least one flap is configured to fold so as to overlap with at least a portion of the end in which the flap is located. Example 82: The aerosol-generating article according to Example 81, wherein at least one flap is configured to be folded by the user. Example 83: The aerosol-generating article according to either one of Embodiments 81 or 82, wherein at least one flap is configured to fold, for example, to cover the opening and / or to extend into the opening, so as to cover at least a portion of an opening defined at the end where the at least one flap is located. Example 84: An aerosol-generating article according to any one of Examples 81 to 83, wherein at least one flap is provided with a flap, and the flap is connected to the article by a fold, such as a score line. Example 85: The aerosol-generating article according to Example 84, wherein the flap extends between the fold and the edge of the flap. Example 86: An aerosol-generating article according to either Example 84 or 85, wherein the fold is curved, for example, concavely curved with respect to the longitudinal dimension of the article. Example 87: An aerosol-generating article according to any one of Examples 84 to 86, wherein the flap edge is curved, for example, curved convexly with respect to the longitudinal dimension of the article. Example 88: The aerosol-generating article according to Example 85, wherein the fold is located adjacent to an opening defined at the edge where the flap is located. Example 89: The aerosol-generating article according to Example 88, wherein the flap is configured to fold along a crease such that the flap overlaps with at least a portion of the opening. Example 90: The aerosol generating article according to either Example 88 or 89, wherein the flap is configured to fold along a crease such that the flap edge is located within the opening, for example, so that the flap edge contacts the inner wall of the aerosol generating article, for example, the inner wall of a chamber accessed through the opening. Example 91: An aerosol generating article according to any one of Examples 81 to 90, wherein the flaps or each flap is arched. Example 92: An aerosol-generating article according to any one of Examples 81 to 91, wherein the flap or each flap is lens-shaped or elliptical-shaped. Example 93: An aerosol-generating article according to any one of Examples 81 to 92, wherein at least one flap is permeable to air. Example 94: An aerosol-generating article according to any one of Examples 81 to 93, wherein at least one through-hole is defined through at least one flap. Example 95: An aerosol generating article according to any one of Examples 81 to 94, wherein at least one flap comprises an air-permeable material, such as a porous material, such as a filter material. Example 96: An aerosol generating article according to any one of Examples 81 to 95, wherein at least one through-hole is defined within at least one flap, and an air-permeable material is bonded to the flap overlapping the through-hole so that air can pass through at least one through-hole and the air-permeable flap. Example 97: An aerosol-generating article according to any one of Examples 81 to 96, wherein at least one through hole has a diameter of 0.1 mm to 1 mm, for example 0.2 mm to 0.75 mm, for example 0.3 mm to 0.5 mm. Example 98: An aerosol generating article according to any one of Examples 81 to 97, wherein the flap provides a drawdown resistance (RTD) of 10 mmH2O to 50 mmH2O with respect to the air passing through the flap. Example 99: An aerosol-generating article according to any one of Examples 81 to 98, wherein the article has a drawdown resistance (RTD) of 10 mmH2O to 50 mmH2O with respect to the air passing through the article between a first end and a second end. Example 100: An aerosol-generating article according to any one of Examples 81 to 99, wherein at least one flap is multiple flaps. Example 101: The aerosol-generating article according to any one of Examples 81 to 100, wherein at least one flap is made up of two flaps, for example, an upper flap and a lower flap. Example 102: The aerosol generating article according to Example 101, comprising an upper flap attached to the aerosol generating article at an upper fold and a lower flap attached to the aerosol generating article at a lower fold, wherein the lower flap is configured to fold upward and the upper flap is configured to fold downward. Example 103: The aerosol-generating article according to Example 102, wherein both the upper and lower flaps overlap with at least a portion of the edge to which the flaps are located, for example, both the upper and lower flaps overlap and / or straddle an opening defined at the edge to which the flaps are located. Example 104: The aerosol-generating article according to either Example 102 or 103, wherein both the upper and lower flaps overlap when folded, overlapping at least a portion of the edge where the flaps are located, for example, spanning an opening defined at the edge where the flaps are located. Example 105: An aerosol-generating article according to any one of Examples 102 to 104, wherein the upper flap and the lower flap are configured to engage with each other when folded and overlap with at least a portion of the edge in which the flap is located. Example 106: The aerosol-generating article according to Example 105, wherein a tab defined on one of the upper and lower flaps engages with a slot defined on the other of the upper or lower flap such that it folds and overlaps with at least a portion of the edge where the flap is located. Example 107: An aerosol-generating article according to any one of Examples 81 to 96, wherein at least one flap is a single flap. Example 108: The aerosol generating article according to any one of Examples 81 to 107, wherein at least one flap is at least one first end flap located at the first end, and the at least one first end flap is configured to fold so as to overlap at least a portion of an opening defined at the first end. Example 109: The aerosol generating article according to Example 108, wherein at least one first end flap is configured to fold so as to at least partially cover an opening defined by the first end, for example, to cover an opening defined by the first end, or to extend into an opening defined by the first end. Example 110: An aerosol-generating article according to either one of Embodiments 108 or 109, wherein at least one first end flap is configured to be folded by the user so as to straddle the opening. Example 111: The aerosol generating article according to any one of Examples 81 to 110, wherein at least one flap is at least one second end flap located at the second end, and at least one second end flap is configured to fold so as to overlap at least a portion of an opening defined at the second end. Example 112: The aerosol generating article according to Example 111, wherein at least one second end flap is configured to fold so as to at least partially cover the opening defined by the second end, for example, to cover the opening defined by the second end, or to extend into the opening defined by the second end. Example 113: An aerosol-generating article according to either one of Examples 111 or 112, wherein at least one second end flap is configured to be folded by the user so as to straddle the opening. Example 114: An aerosol-generating article according to any one of Examples 81 to 113, wherein at least one first end flap is located at the first end and is configured to fold over and / or across an opening defined at the first end, and at least one second end flap is located at the second end and is configured to fold over and / or across an opening defined at the second end. Example 115: An aerosol generating article according to any one of Examples 81 to 114, wherein the first end is the distal end, the second end is the proximal or oral end, and the proximal or oral end faces the distal end. Example 116: An aerosol-generating article according to any one of Examples 81 to 115, wherein the airflow path is defined to or from the article through an opening located at least one of the first and second ends of the article. Example 117: An aerosol generating article according to any one of Examples 81 to 116, wherein the airflow path connects to the article through an opening defined at a first end of the article and exits from the article through an opening defined at a second end of the article, and the airflow path extends into the article between the first and second ends. Example 118: An aerosol generating article according to any one of Examples 81 to 117, wherein an airflow path extending in the longitudinal direction between a first end and a second end is defined within the article, and the airflow path is defined within a peripheral wall that extends between the first end and the second end and surrounds the airflow path in the circumferential direction. Example 119: An aerosol-generating article according to any one of Examples 81 to 118, particularly Example 118, wherein the outer surface of the article is defined by a peripheral wall, the peripheral wall is deformable in an axial cross-section and configured to expand from a contracted first state to an expanded second state, and in the expanded second state, the peripheral wall surrounds a hollow tubular cavity. Example 120: The aerosol-generating article according to Example 119, in which no hollow tubular cavity exists in the first contracted state. Example 121: The aerosol-generating article according to either Example 119 or 120, wherein in the first contracted state, the opposing inward surfaces of the peripheral walls are in surface contact with each other. Example 122: In the expanded second state, the aerosol generating article according to any one of Examples 119 to 121, wherein the peripheral wall of the aerosol generating article is lenticular in its axial cross-section. Example 123: An aerosol-generating article according to any one of Examples 119 to 122, wherein at least one flap is configured to fold to a position in which at least one flap acts to prevent the surrounding wall from contracting from its expanded state to its contracted state. Example 124: An aerosol generating article according to any one of Examples 119 to 123, wherein the peripheral wall of the aerosol generating article is configured to define a band, and the peripheral wall is lens-shaped in an axial cross-section. Example 125: It is a package, Multiple aerosol-generating articles, for example, the aerosol-generating article described in any one of Examples 1 to 124, A container that can receive multiple aerosol-generating articles, A package in which each aerosol-generating article extends along its long axis between two opposing ends, and the peripheral walls of the aerosol-generating articles define a flat shape that is contracted in the axial cross-section. Example 126: The package according to Example 125, wherein, for one or more of the multiple aerosol-generating articles, the opposing inward-facing surfaces of the surrounding walls of each aerosol-generating article are in surface contact with each other. Example 127: The package according to either Example 125 or 126, wherein for one or more of the multiple aerosol-generating articles, the opposing outward-facing surfaces of the peripheral walls of each aerosol-generating article are parallel to each other. Example 128: The package according to any one of Examples 125 to 127, wherein for one or more of the multiple aerosol-generating articles, the opposing outward-facing surfaces of the surrounding walls of each aerosol-generating article are generally flat. Example 129: The package according to any one of Examples 125 to 128, wherein adjacent aerosol-generating articles among multiple aerosol-generating articles are positioned side-by-side within the container, or end-to-end within the container, or a combination thereof. Example 130: The package according to any one of Examples 125 to 129, wherein at least one lid is attached to the container and configured to move from an open position to a closed position, and in the closed position the lid covers a plurality of aerosol-generating articles received inside the container. Example 131: A package according to any one of Examples 125 to 130, wherein each of the multiple aerosol-generating articles conforms to one of the aerosol-generating articles of Examples 1 to 124. Example 132: A package according to any one of Examples 125 to 131, wherein each of the multiple aerosol-generating articles conforms to any one of Examples 18 to 23. Example 133: A package according to any one of Examples 125 to 132, wherein each of the multiple aerosol-generating articles conforms to any one of Examples 24 to 29. Example 134: The package according to Example 133, wherein each of the multiple aerosol-generating articles received in the container is in a first contracted state. Example 135: An apparatus comprising an aerosol generating article, for example, the aerosol generating article described in any one of Examples 1 to 134, shaped into a funnel, and having a cavity configured to expand the aerosol generating article from a flat cross-sectional shape to a lenticular cross-sectional shape along at least a portion or all of the length of the aerosol generating article. Example 136: An apparatus comprising a cavity and a pin, wherein the pin is positioned within the cavity and is inserted into an aerosol generating article that is funnel-shaped along the cavity, thereby expanding the aerosol generating article from a flat cross-sectional shape to a lenticular cross-sectional shape along at least a portion or all of its length, such as the apparatus described in Example 135. Example 137: A system comprising the apparatus according to either Example 135 or 136, further comprising an aerosol generating article having a first state in which the article has a flat cross-sectional shape, and a second state in which the article has a lenticular cross-sectional shape.

[0120] The present invention will be further described, for illustrative purposes only, with reference to the attached drawings.

[0121] Figure 1 shows a perspective view of an aerosol-generating article 100 with a length L extending between a first end 101 and a second end 102. The aerosol-generating article 100 has a peripheral wall 110 extending between the first end 101 and the second end 102. The aerosol-generating article 100 is shown in Figures 1 and 2 as expanded or in an expanded state, and the peripheral wall 110 surrounds a hollow cavity 103 extending along the length L of the article between the first end 101 and the second end 102. The peripheral wall 110 shown in Figures 1 and 2 has a substantially lenticular cross-section. The lenticular cross-section resembles the contour of a biconvex lens, with the upper half portion 111 and the lower half portion 112 of the peripheral wall 110 being mirror images of each other, each having an outward-facing convex surface. The upper half 111 and the lower half 112 of the peripheral wall 110 intersect at opposing lateral edges 113, 114 of the peripheral wall. The distance between the laterally opposing edges 113 and 114 of the peripheral wall 110 defines the width W of the aerosol-generating article 100. The distance between the outermost surfaces of the upper half portion 111 and the lower half portion 112 of the intermediate peripheral wall 110 between the opposing lateral edges 113 and 114 corresponds to the thickness T of the aerosol-generating article 100. Naturally, the thickness dimension T of the aerosol-generating article 100 can also be considered to represent the height of the aerosol-generating article. The upper half portion 111 and the lower half portion 112 may meet at the opposing lateral edges 113 and 114 to define a sharp edge, but the edge typically has a small radius of curvature R1 associated with it, as shown in the detailed view of area B in Figure 2. The radius of curvature R1 may be, for example, less than 2 millimeters. Furthermore, as shown in the detailed view of region B in Figure 2, at the positions of the opposing lateral edges 113 and 114, the acute angle α is defined between the tangent to the outer surface of the upper half portion 111 and the tangent to the outer surface of the lower half portion 112. The acute angle α may be in the range of, for example, 15 to 110 degrees.

[0122] The first end 101 forms the distal end of the aerosol-generating article 100, and the second end 102 forms the proximal end of the aerosol-generating article. The distal end 101 may also be called the mouth end of the aerosol-generating article 100. For the aerosol-generating article 100 in Figures 1 and 2, the first end 101 is an open end. Figure 2 shows the aerosol-generating article 100 when held between the user's thumb and fingers, and the figure is generally viewed along the longitudinal axis LA of the article through the opening of the first end 101 downstream toward the second end 102.

[0123] In the embodiment of the aerosol generating article 100 shown in Figures 1 and 2, the internal cavity 103 surrounded by the peripheral wall 110 has no obstructions between the first end 101 and the second end 102. However, as shown in Figure 2, an optional flap is provided at the second end 102 of the aerosol generating article 100, which substantially covers the opening defined at the second end 102 by the peripheral wall 100. The flap is provided with a through hole.

[0124] Although not shown in the schematic diagrams of Figures 1 and 2, the peripheral wall 110 of the aerosol-generating article 100 includes an aerosol-generating substrate as a component. The aerosol-forming substrate may include homogenized tobacco material and an aerosol-forming material such as propylene glycol or other suitable aerosol-forming material.

[0125] Figures 3A to 3C represent three different embodiments of the peripheral walls 210, 210', and 210'' of the aerosol-generating article 100, with each figure showing an exemplary structure of a peripheral wall segment corresponding to area A in Figure 1.

[0126] In the embodiment shown in Figure 3A, the peripheral wall 210 has an inner layer 211 of a support substrate material such as cardboard. The inner layer 211 of the support substrate is superimposed on a layer 212 of aerosol-forming substrate. The layer 212 of aerosol-forming substrate is then superimposed on a further layer of support substrate 213, such as cardboard. Finally, a cigarette paper wrapper 214 is superimposed on the further layer of support substrate 213 to form the outer surface of the peripheral wall 210. Thus, in the embodiment shown in Figure 3A, the peripheral wall 210 has a layer 212 of aerosol-forming substrate sandwiched between the layers 211 and 213 of the support substrate. The cardboard support substrate material provides most of the bending rigidity of the peripheral wall 210. Naturally, the layers of support substrate 211 and 213 may be different from each other, or they may be formed from a common sheet of support substrate folded around creases to define each of the layers 211 and 213.

[0127] The embodiment in Figure 3B represents the opposite structure to that in Figure 3. More specifically, the peripheral wall 210' has an inner layer 211' of aerosol-forming substrate. The inner layer 211' of the aerosol-forming substrate is superimposed on a layer 212' of a support substrate material such as cardboard. The layer 212' of the support substrate material is then superimposed on a further layer 213' of the aerosol-forming substrate. Finally, the cigarette paper wrapper 214' is superimposed on the further layer 213' of the aerosol-forming substrate to form the outer surface of the peripheral wall 210'. Therefore, in the embodiment of Figure 3B, the peripheral wall 210' has a layer 212' of cardboard support substrate sandwiched between the layers 211' and 213' of the aerosol-forming substrate. In the embodiment of Figure 3A, the cardboard support substrate material provides most of the bending rigidity of the peripheral wall 210'. Naturally, the layers of aerosol-forming substrates 211' and 213' may be different from each other, or they may be formed from a common sheet of aerosol-forming substrate folded around creases to define each of the layers 211' and 213'.

[0128] The embodiment of the peripheral wall 210" shown in Figure 3C does not include separate layers of aerosol-forming substrate and support substrate material. Rather, the peripheral wall 210" in the embodiment of Figure 3C is formed of a layer of aerosol-forming substrate 211" covered with a cigarette paper wrapper 212"." In the embodiment of Figure 3C, the aerosol-forming substrate provides most of the bending rigidity of the peripheral wall 210". The layer of aerosol-forming substrate 211" may have a greater thickness than that of the layer of aerosol-forming substrate used for the peripheral walls 210, 210' in Figures 3A and 3B.

[0129] The extended state of the aerosol-generating article 100 shown in Figures 1 and 2 represents a state in which the article is ready for use and consumption. The user consumes the article 100 by applying heat to the peripheral wall 110 of the aerosol-forming article. In a preferred embodiment, heat is applied to the aerosol-generating article 100 at a level sufficient to heat the aerosol-forming substrate of the peripheral wall 110 but without combustion or ignition. Vapors emitted from the heating of the aerosol-forming substrate are emitted inside the aerosol-generating article 100 and are carried by the airflow drawn through the first end 101 by the user who inhales the mouth end 102. The vapors cool and condense as they flow downstream toward the mouth end 102 to form an aerosol, which the user inhales through the mouth end. In a preferred embodiment, heat may be applied by using an aerosol generator having an electrically operated heating arrangement, using a device configured to receive the aerosol-generating article 100. For example, the aerosol generator may include a chamber for receiving at least a portion of the length of the aerosol-generating article 100. In particularly preferred embodiments, resistance heating arrangements or induction heating arrangements may be used by the aerosol generator to apply heat to the aerosol generating article. However, this disclosure relates to the design and configuration of an aerosol generating article, and it will be understood that other means may be used to apply heat to the aerosol generating article in order to generate an aerosol.

[0130] Figures 4A and 4B illustrate embodiments of an aerosol-generating article 300 in which the article is deformable between two geometric states. Figure 4A shows the aerosol-generating article 300 in a contracted first state. Figure 4B shows the aerosol-generating article 300 in an expanded second state, which generally corresponds to the states of article 100 shown in Figures 1 and 2. The contracted first state is a state in which the area enclosed by the peripheral wall 310 is smaller than the area enclosed by the peripheral wall in the expanded second state. In the contracted first state of Figure 4A, the aerosol-generating article 300 has a thickness T1 that is smaller than the thickness T2 of the article in the expanded second state. Naturally, the thickness dimensions T1, T2 of the aerosol-generating article 300 can also be considered to represent the height of the aerosol-generating article.

[0131] Therefore, in the first contracted state shown in Figure 4A, the aerosol-generating article 300 is flatter and has a wider cross-section than in the second expanded state shown in Figure 4B. The first contracted state in Figure 4A represents the aerosol-generating article 300 in a state optimized for packaging multiple aerosol-generating articles side by side, as will be described in more detail below with reference to Figure 6. For the aerosol-generating article 300 in Figure 4A, the peripheral wall 310 has upper and lower planar portions 311, 312 joined by a pair of laterally opposing folds 313, 314 defined in the peripheral wall. The upper and lower planar portions 311, 312 of the peripheral wall 310 are aligned parallel to each other. In the embodiment shown in Figure 4A, the inward-facing surfaces of the upper planar portion 311 and the lower planar portion 312 are positioned to be in contact with or nearly in contact with each other such that the aerosol-generating article 300 in the contracted first state shown in Figure 4A has a thickness T1 that is approximately twice, or slightly greater than, the thickness t of the upper and lower portions 311 and 312. The user moves the aerosol-generating article 300 from the contracted first state to the expanded second state by pressing the laterally opposed edges of the peripheral wall 310, defined by the folds 313, 314 of the peripheral wall, as indicated by the arrows in Figure 4A. The force applied to the laterally opposed edges 313, 314 of the peripheral wall 310 overcomes the rigidity of the peripheral wall, resulting in a contraction in the width of the aerosol-generating article 300. As the width contracts, the upper and lower planar portions 311, 312 of the peripheral wall 300 separate from each other, increasing the thickness (or height) of the aerosol-generating article and reaching the expanded second state shown in Figure 4B. As can be seen by comparing Figures 4A and 4B, the surrounding wall 310 of the aerosol-generating article 300 encloses a larger area in the expanded second state than in the contracted first state. Compared to the thickness T1 (or height) and width W1 associated with the contracted first state, the aerosol-generating article 300 has increased thickness T2 (or height) and decreased width W2 in the expanded second state.

[0132] Figures 5A and 5B represent alternative embodiments of the aerosol-generating article 400 compared to those in Figures 4A and 4B. With respect to the embodiments of Figures 4A and 4B, the article 400 in Figures 5A and 5B is deformable between a contracted first state and an expanded second state, respectively. The expanded second state in Figure 5B is essentially the same as that of the embodiment in Figure 4B. However, the axial cross-sectional shape of the aerosol-generating article in the contracted first state differs in the article 400 in Figure 5A compared to the article 300 in Figure 4A. In contrast to the planar structure of the peripheral wall 310 used in Figure 4A, in the embodiment of Figure 5A, the peripheral wall 410 has upper and lower convex portions 411, 412 joined by a pair of laterally opposing folds 413, 414 defined in the peripheral wall. Thus, the aerosol-generating article 400 has a generally lenticular cross-section in both the contracted first state (see Figure 5A) and the expanded second state (see Figure 5B). The use of the lenticular cross-section of article 400 in the contracted first state facilitates the transition from the contracted first state to the expanded second state. Further explanation is given that the outward curvature of the upper and lower convex portions 411, 412 of the peripheral wall 410 in the contracted first state in Figure 5A means that the peripheral wall is easily deformed into the expanded second state when the user presses on the laterally opposing edges 413, 414 of the peripheral wall.

[0133] Figure 6 shows package 5000. Package 5000 has a container 5100 that houses a plurality of aerosol-generating articles 400 in a shrunk first state, as shown in Figure 5A above. The shallow thickness of the aerosol-generating articles 400 in the shrunk first state allows multiple different aerosol-generating articles to be stored inside the holder 5100 adjacent to each other in a space-efficient manner, while minimizing the air gap between adjacent aerosol-generating articles. For package 5000 in Figure 6, a lid 5200 is attached to the container 5100. The lid 5200 is hinged to the container 5100, allowing the lid to be opened to expose the inside of the container and allowing a user to remove a given one of the aerosol-generating articles 400 from inside the container. Next, the user may press the laterally opposing sides 413, 414 of the removed aerosol generating article 400 to transition the article from a contracted first state (Figure 5A) to an expanded second state (Figure 5B) in preparation for heating and consumption.

[0134] Figures 7A-7C, 8A-8C, 9A-9C, 10A-10C, 11, and 12 illustrate various different structures of the peripheral wall of an aerosol-generating article, each illustrating the peripheral wall in an axial cross-section of the aerosol-generating article in an expanded second state.

[0135] Figure 7A shows an embodiment having a single sheet 511 of a support substrate (e.g., a support substrate formed from cardboard) such that the peripheral wall 510 is folded around a fold 512 such that a first portion 513 of the support substrate rests on a second portion 514 of the support substrate. The first portion 513 and the second portion 514 of the support substrate sheet 511 form the first and second halves, respectively, of the circumferential length of the peripheral wall 510. The first inner sheet 515 of the aerosol-forming substrate rests on the inward-facing surface of the first portion 513 of the support substrate sheet 511. The second inner sheet 516 of the aerosol-forming substrate rests on the inward-facing surface of the second portion 514 of the support substrate sheet 511. The cigarette paper wrapper 517 forms the outer surface of the peripheral wall 510.

[0136] Figure 7B shows an alternative embodiment of the peripheral wall 510' compared to that in Figure 7A. This embodiment differs from that in Figure 7A in that the peripheral wall 510' does not have a first inner sheet and a second inner sheet of the aerosol-forming substrate, but instead has a first outer sheet 515' and a second outer sheet 516' of the aerosol-forming substrate. The first outer sheet 515' of the aerosol-forming substrate rests on the outward-facing surface of the first portion 513 of the sheet 511 of the support substrate. The second outer sheet 516' of the aerosol-forming substrate rests on the outward-facing surface of the second portion 514 of the sheet 511 of the support substrate. The cigarette paper wrapper 517 forms the outer surface of the peripheral wall 510'.

[0137] Figure 7C shows an alternative embodiment of the peripheral wall 510” compared to those in Figures 7A and 7B. The embodiment in Figure 7C represents a combination of the embodiments in Figures 7A and 7B, in which the peripheral wall 510” incorporates both the first inner sheet 515 and the second inner sheet 516 of the aerosol-forming substrate, as well as the first outer sheet 515' and the second outer sheet 516' of the aerosol-forming substrate. Thus, in the embodiment of Figure 7C, the opposing surfaces of the first portion 513 of the sheet 511 of the support substrate are sandwiched between the first inner sheet 515 and the outer sheet 515' of the aerosol-forming substrate, and similarly, the opposing surfaces of the second portion 514 of the sheet 511 of the support substrate are sandwiched between the second inner sheet 516 and the outer sheet 516' of the aerosol-forming substrate. The cigarette paper wrapper 517 forms the outer surface of the peripheral wall 510”.

[0138] Figures 8A–8C show three different embodiments of the peripheral walls 610, 610', and 610''. The embodiments in Figures 8A–8C differ from those in Figures 7A–7C in the configuration of the support base. More specifically, instead of employing a single sheet of support base folded around a crease to define the first and second halves of the circumferential length of the peripheral wall, the embodiments in Figures 8A–8C employ separate first and second sheets 611 and second sheets 612 of the support base. The first and second sheets 612 of the support base are arranged opposite each other such that their laterally opposing edges align to define the laterally opposing edges 613 and 614 of the peripheral wall. The first and second sheets 611 and second sheets 612 of the support base form the first and second halves, respectively, of the circumferential length of the peripheral wall. The cigarette paper wrapper 615 forms the outer surface of the peripheral wall.

[0139] In the embodiment of the peripheral wall 610 in Figure 8A, the first inner sheet 616 of the aerosol-forming substrate rests on the inward-facing surface of the first sheet 611 of the support substrate, and the second inner sheet 617 of the aerosol-forming substrate rests on the inward-facing surface of the second sheet 612 of the support substrate.

[0140] In the embodiment of the peripheral wall 610' in Figure 8B, the first outer sheet 616' of the aerosol-forming substrate rests on the outward-facing surface of the first sheet 611 of the support substrate, and the second outer sheet 617' of the aerosol-forming substrate rests on the outward-facing surface of the second sheet 612 of the support substrate.

[0141] In the embodiment of the peripheral wall 610" in Figure 8C, the opposing surfaces of the first sheet 611 of the support substrate are sandwiched between the first inner sheet 616 and the outer sheet 616' of the aerosol-forming substrate, and similarly, the opposing surfaces of the second sheet 612 of the support substrate are sandwiched between the second inner sheet 617 and the outer sheet 617' of the aerosol-forming substrate.

[0142] Figures 9A-9C and 10A-10C represent inverse embodiments of the peripheral walls relative to those in Figures 7A-7C and 8A-8C, respectively. These embodiments are outlined in more detail below.

[0143] Figure 9A shows an embodiment of the peripheral wall 710, which has a single sheet 711 of aerosol-forming substrate, folded around a fold 712 such that a first portion 713 of the aerosol-forming substrate lies on a second portion 714 of the aerosol-forming substrate. The first portion 713 and the second portion 714 of the sheet 711 of the aerosol-forming substrate form the first and second halves, respectively, of the circumferential length of the peripheral wall 710. The first inner sheet 715 of the support substrate lies on the inward-facing surface of the first portion 713 of the sheet 711 of the aerosol-forming substrate. The second inner sheet 716 of the support substrate lies on the inward-facing surface of the second portion 714 of the sheet 711 of the aerosol-forming substrate. The support substrate may be formed from cardboard. A cigarette paper wrapper 717 forms the outer surface of the peripheral wall 710.

[0144] Figure 9B shows an alternative embodiment of the peripheral wall 710' compared to that in Figure 9A. This embodiment differs from the embodiment in Figure 9A in that it does not have first and second inner sheets of the support substrate, but has first and second outer sheets 715', 716' of the support substrate. The first outer sheet 715' of the support substrate rests on the outward-facing surface of the first portion 713 of the aerosol-forming substrate sheet 711. The second outer sheet 716' of the support substrate rests on the outward-facing surface of the second portion 714 of the aerosol-forming substrate sheet 711. The cigarette paper wrapper 717 forms the outer surface of the peripheral wall 710'.

[0145] Figure 9C shows an alternative embodiment of the peripheral wall 710” compared to those in Figures 9A and 9B. The embodiment in Figure 9C represents a combination of the embodiments in Figures 9A and 9B, incorporating both the first inner sheet 715 and the second inner sheet 716 of the support substrate, as well as the first outer sheet 715' and the second outer sheet 716' of the support substrate. Thus, in the embodiment of Figure 9C, the opposing surfaces of the first portion 713 of the aerosol-forming substrate sheet 711 are sandwiched between the first inner sheet 715 and the outer sheet 715' of the support substrate, and similarly, the opposing surfaces of the second portion 714 of the aerosol-forming substrate sheet 711 are sandwiched between the second inner sheet 716 and the outer sheet 716' of the support substrate. The cigarette paper wrapper 717 forms the outer surface of the peripheral wall 710”.

[0146] Figures 10A to 10C show three different embodiments of the peripheral walls 810, 810', and 810''. The embodiments in Figures 10A to 10C differ from the embodiments in Figures 9A to 9C in the configuration of the aerosol-forming substrate. More specifically, instead of employing a single sheet of aerosol-forming substrate folded around a crease to define the first and second halves of the circumference of the peripheral wall, the embodiments in Figures 10A to 10C employ separate first sheet 811 and second sheet 812 of the aerosol-forming substrate. The first sheet 811 and the second sheet 812 of the aerosol-forming substrate are arranged facing each other such that their laterally opposing edges align to define laterally opposing edges 813 and 814 of the peripheral wall. The first sheet 811 and the second sheet 812 of the aerosol-forming substrate form the first and second halves, respectively, of the circumferential length of the peripheral wall. The cigarette paper wrapper 815 forms the outer surface of the peripheral wall.

[0147] In the embodiment of the peripheral wall 810 in Figure 10A, the first inner sheet 816 of the support substrate rests on the inward-facing surface of the first sheet 811 of the aerosol-forming substrate, and the second inner sheet 817 of the support substrate rests on the inward-facing surface of the second sheet 812 of the aerosol-forming substrate.

[0148] In the embodiment of the peripheral wall 810' in Figure 10B, the first outer sheet 816' of the support substrate rests on the outward-facing surface of the first sheet 811 of the aerosol-forming substrate, and the second outer sheet 817' of the support substrate rests on the outward-facing surface of the second sheet 812 of the aerosol-forming substrate.

[0149] In the embodiment of the peripheral wall 810" in Figure 10C, the opposing surfaces of the first sheet 811 of the aerosol-forming substrate are sandwiched between the first inner sheet 816 and the outer sheet 816' of the support substrate, and similarly, the opposing surfaces of the second sheet 812 of the aerosol-forming substrate are sandwiched between the second inner sheet 817 and the outer sheet 817' of the support substrate.

[0150] In each of the embodiments shown in Figures 7A-7C, 8A-8C, 9A-9C, and 10A-10C, the peripheral wall is formed by a combination of a support substrate material and an aerosol-forming substrate. The support substrate may function to provide most of the bending rigidity of the peripheral wall and may be considered to support the aerosol-forming substrate. The support substrate may be formed from an air-permeable material, thereby allowing vapors generated by heating the aerosol-forming substrate to pass through the thickness of the support substrate. For example, if the peripheral wall is positioned on the outward-facing surface of the sheet of the support substrate, employing an air-permeable material for the support substrate facilitates the passage of vapors (when heated) from the aerosol-forming substrate surrounded by the peripheral wall into the internal volume of the aerosol-generating article through the support substrate. Air permeability may be provided by the use of one or more porous materials for the support substrate. Alternatively, as described in the following paragraphs, air permeability may be provided by providing openings extending through the peripheral wall.

[0151] In further alternative embodiments of the peripheral walls 910, 910' described with reference to Figures 11 and 12, the peripheral walls lack a combination of separate sheets of support substrate and aerosol-forming substrate.

[0152] Figure 11 shows an embodiment of the peripheral wall 910, which has a single sheet 911 of aerosol-forming substrate, folded around a fold 912 such that a first portion 913 of the aerosol-forming substrate sheet is on top of a second portion 914 of the aerosol-forming substrate sheet. The first portion 913 and the second portion 914 of the aerosol-forming substrate sheet 911 form the first and second halves, respectively, of the circumferential length of the peripheral wall 910. The single sheet 911 of aerosol-forming substrate is thicker than any of the aerosol-forming substrate sheets described in relation to the embodiments of Figures 7A-7C, 8A-8C, 9A-9C, and 10A-10C, allowing the aerosol-forming substrate to provide the aerosol-generating article 910 with a desired level of bending rigidity. The cigarette paper wrapper 915 forms the outer surface of the peripheral wall 910.

[0153] The embodiment of the peripheral wall 910' in Figure 12 differs from the embodiment in Figure 11 in the configuration of the aerosol-forming substrate. More specifically, instead of employing a single sheet of aerosol-forming substrate folded around a crease to define the first and second halves of the circumferential length of the peripheral wall, the embodiment in Figure 12 employs separate first sheet 911' and second sheet 912' of the aerosol-forming substrate. The first sheet 911' and second sheet 912' of the aerosol-forming substrate are arranged facing each other such that their laterally opposing edges align to define the laterally opposing edges 913' and 914' of the peripheral wall. The first sheet 911' and second sheet 912' of the aerosol-forming substrate form the first and second halves, respectively, of the circumferential length of the peripheral wall 910'. The cigarette paper wrapper 915 also forms the outer surface of the peripheral wall.

[0154] Figures 13A and 13B illustrate further embodiments of the aerosol-generating article 1000 in an expanded state, the article having a peripheral wall 1010 with an axial cross-section lenticular. As shown in Figure 13A, the axially extending portion 1011 of the peripheral wall 1010 of the aerosol-generating article 1000 is provided with a plurality of circular openings 1012 extending through the thickness of the peripheral wall. The openings 1012 may be called “through holes” because they extend through the thickness of the peripheral wall 1010. The peripheral wall 1010 of the aerosol-generating article 1000 is formed of a support substrate material and optionally includes a cigarette paper wrapper located outside the support substrate. Cardboard is an example of a suitable material for forming the support substrate of the peripheral wall 1010. As shown in Figure 13B, a strip 1013 of the aerosol-forming substrate is sleeved around the peripheral wall 1010 and covers the plurality of openings 1012 formed within the axially extending portion 1011 of the peripheral wall. The aerosol-forming substrate strip 1013 has an axial length slightly greater than the length of the axially extending portion 1011 of the peripheral wall 1010 where the opening 1012 is defined. The aerosol-forming substrate strip 1013 may be formed as a single sheet of aerosol-forming substrate wound around the circumferential length of the peripheral wall 1010. Alternatively, a first sheet of aerosol-forming substrate may be placed over the opening 1012 defined in the upper convex portion 1014 of the peripheral wall 1010, and a second sheet of aerosol-forming substrate may be superimposed over the opening defined in the lower convex portion 1015 of the peripheral wall. Based on sufficient heat to be applied to the aerosol-forming substrate strip 1013 to release volatile compounds from the aerosol-forming substrate and form vapor, the opening 1012 in the axially extending portion 1011 of the peripheral wall 1010 allows the vapor to enter the internal space of the aerosol-generating article 1000 surrounded by the peripheral wall. The aerosol-forming substrate band 1013 and the opening 1012 are positioned closer to the first end 1001 of the aerosol-generating article 1000 than to the second (or mouth-side) end 1002 of the aerosol-generating article. The opening 1012, defined in the axially extending portion 1011 of the peripheral wall 1010, is shown as circular in the embodiment of Figure 13A, but any other shape may be used for the opening to allow vapor flow through the opening across the thickness of the peripheral wall 1010.

[0155] Any particular embodiment of an aerosol-generating article described herein may include one or more end flaps configured to at least partially cover the edges of the aerosol-generating article. Exemplary embodiments of such aerosol-generating articles are described with reference to Figures 14-24. Figures 14-18 illustrate the protrusions of the aerosol-generating article 1100 when configured in a contracted or flat state. Figure 19 illustrates the article 1100 transitioning from a contracted state to an expanded or extended state. Figures 20-24 illustrate the protrusions of the article 1100 in that expanded or extended state.

[0156] Article 1100 is configured to deform for use from a first state, which is contracted or flat, to a second state, which is expanded or extended. In the first contracted state illustrated in Figures 14-18, article 1100 is substantially two-dimensional. The aerosol-generating article 1100 extends along its long axis between a first end 1101 and a second end 1102. In relation to other embodiments of the aerosol-generating article described above, the second end 1102 may be referred to as the proximal end or oral end.

[0157] Article 1100 comprises a substantially flat top surface 1110 having a length L substantially extending between a first end 1101 and a second end 1102, and a width W extending between a first transversely opposing edge 1103 and a second transversely opposing edge 1104. In certain embodiments, the length may be 20 mm to 100 mm, for example, about 45 mm. In certain embodiments, the width may be 10 mm to 20 mm, for example, about 15 mm.

[0158] Article 1100 has a substantially flat lower surface 1111 opposite the upper surface 1110. The lower surface 1111 is identical to the upper surface 1110. The sides extend between the upper surface 1110 and the lower surface 1111. In the contracted state, the height (or thickness) of article 1100 is determined by the thickness t of the material forming the peripheral wall 1120 of article 1100. For example, the height (or thickness) of an article in the contracted state may be 0.5 mm to 2.5 mm, for example, about 1 mm.

[0159] The upper flap 1130 is located at the second (or mouth-side) end 1102 of the top surface 1110 of the article 1100. The upper flap 1130 is defined by an upper flap leading edge 1131 shaped as a convex curve extending toward the second end 1102, and an upper flap fold 1132 defined by concave score lines on the top surface 1110. The shape of the upper flap fold 1132 reflects the shape of the upper flap leading edge 1131, and the shape of the upper flap 1130 is primarily lenticular, like a biconvex lens.

[0160] Multiple upper flap through-holes 1135 are defined through the thickness of the upper flap 1130. The upper flap through-holes 1135 are configured to provide an airflow path through the flap 1130 and to provide a filtering effect to prevent large material particles from being inhaled by the user sucking on the article 1100. The holes 1135 may have any suitable dimensions to provide an airflow path. The dimensions of each through-hole 1135 may depend on the total number of through-holes present. In a particular embodiment, for example, there may be 1 to 50 through-holes 1135, for example, 3 to 10 through-holes, for example, about 7 through-holes. The diameter of these through-holes 1135 may be 0.1 mm to 1 mm, for example, 0.2 mm to 0.5 mm.

[0161] The lower flap 1140 is located at the second (or mouth-side) end 1102 of the lower surface 1111 of the article 1100. The lower flap 1140 is defined by a lower flap leading edge 1141 shaped as a convex curve extending toward the second end 1102, and a lower flap fold 1142 defined by a concave score line on the lower surface 1111. The lower flap 1140 also comprises a plurality of lower flap through-holes 1145, which are substantially the same as the upper flap through-holes 1135 described above.

[0162] The article 1100 in this particular embodiment is essentially in the form of a tube of material defined by a peripheral wall 1120, with an upper flap 1130 and a lower flap 1140 defined at the second end 1102 of the article. In the contracted state, the tube is a flat tube, and the inner upper surface 1121 and inner lower surface 1122 of the peripheral wall 1120 are in contact with each other. The peripheral wall 1120 may be any suitable material (e.g., as described for any of the embodiments described above) and may include an aerosol-forming material. For example, the peripheral wall 1120 may be formed from a laminated material having an outer portion formed from paper or cardboard and an inner portion formed from an aerosol-forming material such as homogenized tobacco material. The peripheral wall 1120 may be formed from a plurality of components assembled within a wrapper such as cigarette paper.

[0163] To move article 1100 from a contracted first state to an expanded second state, the user applies pressure to the first and second laterally opposing edges 1103, 1104, moving these edges closer to each other (as illustrated by the arrows in Figure 19). The top surface 1110 and bottom surface 1111 curve outward, increasing the thickness or height of the aerosol-generating article 1100, thereby opening the channel 1150 between the inner top surface 1121 and inner bottom surface 1122 of the peripheral wall 1120. The user then folds the bottom flap 1140 upward around the bottom flap fold 1142 and the top flap 1130 downward around the top flap fold 1132. The curved folds 1132, 1142 associated with each flap 1130, 1140 effectively lock each flap in place when the flap is folded, and help prevent the article 1100 from returning to its contracted first state.

[0164] Figures 20-24 illustrate the article 1100 in its expanded second state, where a channel 1150 is defined by a peripheral wall 1120. This channel 1150 forms an airflow path extending along the long axis through the article 1100 between a first end 1101 and a second end 1102. The upper surface 1110 and lower surface 1111 are curved outward, and the thickness or height of the article 1100 is increased compared to the contracted first state. The height or thickness of the article 1100 may be, for example, 4mm to 10mm, for example, 5mm to 8mm, for example, about 6mm.

[0165] The upper flap 1130 and the lower flap 1140 are folded at the second (or mouth-side) end 1102 to cover the opening to the channel 1150. In the plan view, the second end 1102 shows a concave contour along the upper flap fold 1132 and the lower flap fold 1142. The end projection from the second end 1102 in Figure 23 shows a lenticular cross-section of the article 1100, and the through channel 1150 is covered by the upper flap 1130 and the lower flap 1140.

[0166] As described in other embodiments of the aerosol-generating article, the user transitions the article 1100 from its contracted first state to its expanded second state. The distal end 1101 of the article 1100 may then be positioned to engage with an aerosol-forming device to heat the aerosol-forming substrate of the article. The user inhales the second (or mouth-side) end 1102 of the article 1100, inhaling the aerosol generated by heating the aerosol-forming substrate. The flaps 1130, 1140 help resist pressure from the user's lips, thereby helping to maintain the article 1100 in its expanded state.

[0167] Figures 25-28 illustrate further embodiments of an aerosol generating article 2100 having foldable end flaps. Article 2100 is similar to article 1100 described above, except that both the first end 2101 and the second (or mouth-side) end 2102 of article 2100 are closed by foldable flaps 2160, 2130. The flap 2130 at the second end 2102 has a plurality of through-holes 2135 sized to act as filter holes to prevent the user from inhaling solid particulate matter. The flap 2160 at the first end 2101 defines a plurality of inlet holes 2165 to allow air to flow into article 2100. The inlet holes 2165 may be larger in size than the through-holes 2135 at the second end 2102.

[0168] Article 2100 transitions from a first contracted state to a second expanded state in the same manner as described above, with the difference being that the user folds flaps at both ends of the article. An additional flap 2160 at the distal end or first end 2101 of article 2100 may provide additional structural rigidity to the article during use.

[0169] Figure 29 is a plan view showing a sheet of material 3000 that can be used as a template for forming the peripheral walls of an aerosol-generating article, for example, showing the peripheral walls of aerosol-generating articles 1100 and 2100 in embodiments of Figures 14-24 and 25-28, respectively. The sheet of material 3000 has a "pillow box" shaped contour. The sheet of material 3000 may be provided in a planar form having a first portion 3100 and a second portion 3200 separated by straight score lines 3300. Concave score lines 3101, 3102 are provided close to the opposing ends of the first portion 3100. The score lines 3101, 3102 are complementary in shape to the convex free edges 3103, 3104 at the opposing ends of the first portion 3100. Similarly, concave score lines 3201, 3202 are provided close to the opposing ends of the second portion 3200. The scorelines 3201 and 3202 are complementary in shape to the convex free edges 3203 and 3204 at the opposing ends of the second portion 3200. For the first portion 3100 of the sheet 3000, the first flap 3111 is defined by a concave scoreline 3101 and a convex free edge 3103, and the second flap 3112 is defined by a concave scoreline 3102 and a convex free edge 3104. For the second portion 3200 of the sheet 3000, the first flap 3211 is defined by a concave scoreline 3201 and a convex free edge 3203, and the second flap 3212 is defined by a concave scoreline 3202 and a convex free edge 3204. Tab 3400 is defined along the side of the second portion 3200, and the tab is defined by a straight score line 3401 and a free side edge 3402 of the second portion. Cutouts 3500 are defined on flaps 3111, 3112 respectively, and the cutouts are formed into convex free edges 3103, 3104. The "pillow box" shaped sheet 3000 of the material can be transformed into a peripheral wall by folding the first portion 3100 over the second portion 3200 around the score line 3300.The tabs 3400 may be positioned through corresponding slots (not shown) provided in the first portion 3100 of the sheet 3000, thereby helping to fix the corresponding free side edges of the first portion 3100 and the second portion 3200 together to form a peripheral wall. Alternatively or additionally, the tabs 3400 of the second portion 3200 may be fixed to the first portion 3100 using adhesive. The peripheral wall may initially have a contracted, flat contour in the axial cross-section, similar to those shown in Figures 17 and 18. However, the peripheral wall may then be expanded or deformed into an expanded state in a manner similar to that described for embodiments in Figures 14-24 and 25-28, such that the flaps 3111, 3112, 3211, and 3212 fold around their respective scorelines to at least partially cover the openings defined at both ends of the peripheral wall. The folded flaps 3111, 3112, 3211, and 3212 may help to maintain the surrounding wall in its extended or extended state.

[0170] For the purposes of this specification and the appended claims, unless otherwise indicated, all numerical values ​​representing quantities, amounts, percentages, etc., should be understood in all instances as being modified by the term “approximately.” Furthermore, all ranges include the disclosed maximum and minimum points and any intermediate ranges within that range, which may or may not be specifically listed herein. Thus, in this context, the number “A” is understood as 10% of “A” ± “A.” In this context, the number “A” may be considered to include numerical values ​​that fall within the general standard error of the measurement of the characteristic that the number “A” modifies. In some instances, such as those used in the appended claims, the number “A” may deviate by the percentages listed above, provided that the amount by which “A” deviates does not substantially affect the fundamental and novel characteristics of the claimed invention. Furthermore, all ranges include the disclosed maximum and minimum points and any intermediate ranges within that range, which may or may not be specifically listed herein.

Claims

1. An aerosol generating article extending longitudinally between a first end and a second end, wherein at least one flap is located at one of the first end and the second end, and the at least one flap is configured to fold so as to overlap at least a portion of the end on which the flap is located, and the thickness of the aerosol generating article is less than the length and width of the aerosol generating article, respectively.

2. The aerosol generating article according to claim 1, wherein at least one flap is configured to fold and cover at least a portion of an opening defined at the end where the at least one flap is located, for example, to cover the opening and / or to extend into the opening.

3. The aerosol generating article according to claim 1 or 2, wherein the at least one flap comprises a flap, and the flap is connected to the article by a fold, for example, a score line.

4. The aerosol generating article according to claim 3, wherein the flap extends between the fold and the edge of the flap.

5. The aerosol generating article according to claim 3 or claim 4, wherein the fold is curved, for example, curved concavely with respect to the longitudinal dimension of the article.

6. The aerosol generating article according to any one of claims 3 to 5, wherein the flap edge or the flap edge is curved, for example, curved convexly with respect to the longitudinal dimension of the article.

7. The aerosol generating article according to any one of claims 1 to 6, wherein the flap or each flap is lens-shaped or elliptical-shaped.

8. The aerosol generating article according to any one of claims 1 to 7, wherein at least one of the flaps is permeable to air.

9. The aerosol generating article according to any one of claims 1 to 8, wherein at least one through-hole is defined through at least one flap.

10. The aerosol generating article according to any one of claims 1 to 9, wherein the at least one flap comprises an air-permeable material, such as a porous material, such as a filter material.

11. The aerosol generating article according to any one of claims 1 to 10, wherein the at least one flap comprises an upper flap and a lower flap, the upper flap being attached to the aerosol generating article at an upper fold, and the lower flap being attached to the aerosol generating article at a lower fold, for example, the lower flap being configured to fold upward and the upper flap being configured to fold downward.

12. The aerosol generating article according to claim 11, wherein both the upper flap and the lower flap overlap at least a portion of the end on which the flaps are located, for example, both the upper flap and the lower flap overlap and / or span an opening defined in the end on which the flaps are located.

13. An aerosol generating article according to any one of claims 1 to 12, wherein at least one first end flap is located at the first end and the at least one first end flap is configured to fold over and / or straddle an opening defined at the first end, and at least one second end flap is located at the second end and the at least one second end flap is configured to fold over and / or straddle an opening defined at the second end.

14. The aerosol generating article according to any one of claims 1 to 13, wherein the outer surface of the article is defined by a peripheral wall, the peripheral wall is deformable in an axial cross-section and configured to expand from a contracted first state to an expanded second state, and in the expanded second state, the peripheral wall surrounds a hollow tubular cavity.

15. The aerosol generating article according to claim 14, wherein the at least one flap is configured to fold to a position in which the at least one flap acts to prevent the peripheral wall from contracting from an expanded state to a contracted state.

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