Aerosol-generating article with susceptor and thick wrapper

Abstract

The present invention relates to an aerosol-generating article comprising a longitudinal central axis (22) and an aerosol-forming substrate portion (16) containing a susceptor (20) and an aerosol-forming substrate at least partially defining the susceptor (20). The substrate wrapper (24) at least partially defines the aerosol-forming substrate portion (16), forms an overlapping region of an overlapping end portion of the substrate wrapper (24), has a thickness of 50 microns or greater, and comprises one or more layers having the same length in a direction parallel to the central axis. The flat-plane susceptor (20) portion is oriented such that an angle between a first straight line (30) perpendicular to a flat plane (21) of the flat-plane susceptor portion and a second straight line (32) perpendicular to the central axis (22) and extending from the central axis (22) to a position in the overlap region is between 0 and 25 degrees. The invention also relates to a package comprising a plurality of aerosol-generating articles. The invention also relates to an aerosol-generating system.

Description

Technical Field

[0001] The present disclosure relates to an aerosol-generating article. The present disclosure also relates to a package comprising a plurality of aerosol-generating articles. The present disclosure further relates to an aerosol-generating system. Background Art

[0002] It is known to provide an aerosol-generating device for generating an inhalable vapour. Such a device can heat an aerosol-forming substrate contained in an aerosol-generating article without burning the aerosol-forming substrate. The aerosol-generating article can have a strip shape for inserting the aerosol-generating article into a heating chamber of an aerosol-generating device.

[0003] The aerosol generating device may comprise a heating device. The heating device may be an induction heating device and may comprise an induction coil configured to inductively heat a susceptor. The susceptor may be part of the device or may be part of the aerosol generating article. Summary of the invention

[0004] It is desirable to provide a more efficient aerosol-generating article. It is desirable to provide an aerosol-generating article that requires a smaller amount of aerosol-forming substrate. It is desirable to provide an aerosol-generating article that is more mechanically robust. It is desirable to provide an aerosol-generating article that can be used with existing aerosol-generating devices.

[0005] According to an embodiment of the present invention, an aerosol generating article is provided. The aerosol generating article may include a central axis extending centrally along the longitudinal direction of the aerosol generating article. The aerosol generating article may include an aerosol forming substrate portion. The aerosol forming substrate portion may accommodate a susceptor. The aerosol forming substrate portion may accommodate an aerosol forming substrate. The aerosol forming substrate may at least partially define the susceptor. The aerosol generating article may include a substrate wrapper that at least partially defines the aerosol forming substrate portion. The substrate wrapper may form an overlapping region of overlapping end portions of the substrate wrapper. The substrate wrapper may have a thickness of 50 microns or more. The substrate wrapper may include one or more layers having the same length in a direction parallel to the central axis. The susceptor may include a flat planar susceptor portion. The flat planar susceptor portion may be oriented such that the angle between a first straight line perpendicular to the flat plane of the flat planar susceptor portion and a second straight line perpendicular to the central axis and extending from the central axis to a position in the overlapping region is between 0 degrees and 25 degrees.

[0006] According to an embodiment of the present invention, an aerosol generating article is provided, which includes a central axis extending centrally along the longitudinal direction of the aerosol generating article. The aerosol generating article includes an aerosol forming substrate portion, and the aerosol forming substrate portion accommodates a susceptor and an aerosol forming substrate. The aerosol forming substrate at least partially defines the susceptor. The aerosol generating article includes a substrate wrapper that at least partially defines the aerosol forming substrate portion. The substrate wrapper forms an overlapping region of overlapping end portions of the substrate wrapper. The substrate wrapper has a thickness of 50 microns or more. The substrate wrapper includes one or more layers having the same length in a direction parallel to the central axis. The susceptor includes a flat planar susceptor portion. The flat planar susceptor portion is oriented so that the angle between a first straight line perpendicular to the flat plane of the flat planar susceptor portion and a second straight line perpendicular to the central axis and extending from the central axis to a position in the overlapping region is between 0 degrees and 25 degrees.

[0007] The realization orientation of the flat planar susceptor portion allows the flat planar susceptor portion to be arranged roughly parallel to the overlapping region. When the opposite end portions of the substrate wrapper are pressed onto each other to form the overlapping end portions, this can help to mechanically stabilize the aerosol generating article during manufacture. When the opposite end portions of the thick substrate wrapper are pressed onto each other to close the overlapping end portions, this can particularly help to mechanically stabilize the aerosol generating article during manufacture. When the opposite end portions of the substrate wrapper are pressed onto each other, the aligned flat portion of the susceptor can be used as a stabilizing lower layer.

[0008] The achieved orientation of the flat planar susceptor portion relative to the overlap region of the substrate wrapper may allow the flat planar susceptor portion to be arranged at a greater distance from the overlap region. This may be particularly beneficial when a thick substrate wrapper is used, as the thick substrate wrapper may be arranged closer to the central axis due to its thickness than a thinner substrate wrapper. This may be particularly beneficial when the overall outer diameter of the aerosol-generating article remains constant so that the article can be used with existing aerosol-generating devices.

[0009] Glue may be provided in the overlapping region to adhere the overlapping end portions of the substrate wrapper to each other. During use, the flat planar susceptor portion is heated. Arranging the heated flat planar susceptor portion at a greater distance from the overlapping region may advantageously reduce or avoid undesired heating of the glue. Thus, the mechanical stability of the aerosol generating article may be improved. The generation of odors inadvertently by the heated glue may be reduced or avoided.

[0010] The pit or dead volume can be formed directly adjacent to the overlapping area. The pit can be arranged directly adjacent to the overlapping area in a substantially circumferential direction. The pit can be formed directly adjacent to the edge of the inner end portion of the substrate packaging material, which is wrapped externally by the outer opposite end portion of the substrate packaging material in the overlapping area. The edge of the inner end portion of the substrate packaging material can prevent the aerosol-forming substrate from entering the pit formed at the edge. The pit can act as a dead volume, wherein there is no or only a little aerosol-forming substrate. Positioning the pit at a greater distance from the susceptor means that the pit can be positioned in an area that is less heated by the susceptor. This is due to the thermal gradient around the heating susceptor. Due to the orientation of the flat susceptor portion relative to the overlapping area, the pit can therefore be positioned in an area where the degree of heating in the aerosol-forming part is not as high as the degree of heating in the area closer to the susceptor. Therefore, the waste of heat for heating the dead volume is less. A more effective aerosol-generating article can be provided. In particular, when using a thick substrate packaging material, a more effective aerosol-generating article can be provided because the thick edge of the inner end portion of the thick substrate packaging material can generate a larger pit and a larger dead volume.

[0011] A thick wrapper may reduce the diameter of the aerosol-forming portion defined by the thick wrapper. The reduced diameter of the aerosol-forming portion may improve thermal contact between the aerosol-forming substrate and the susceptor. A more efficient aerosol-generating article may be provided.

[0012] The combination of all layers in one or more layers of substrate wrapper can limit the overall thickness of 50 microns or bigger substrate wrapper.At least one layer in one or more layers of substrate wrapper can have 50 microns or bigger independent thickness.Each layer in one or more layers of substrate wrapper can have 50 microns or bigger independent thickness.

[0013] The substrate wrapper may be arranged such that it does not extend beyond a longitudinal end of the aerosol-forming substrate portion in a direction parallel to the longitudinal direction of the aerosol-generating article.

[0014] The thickness that the matrix package can have is 60 microns or larger, preferably 70 microns or larger, more preferably 75 microns or larger, more preferably 80 microns or larger, more preferably 90 microns or larger, more preferably 100 microns or larger, more preferably 110 microns or larger, more preferably 120 microns or larger, more preferably 130 microns or larger, more preferably 140 microns or larger, more preferably 145 microns or larger, more preferably 150 microns or larger.The matrix package can have the thickness of approximately 148 microns.The matrix package can have the thickness between 143 microns and 153 microns.The matrix package can have the thickness between 140 microns and 160 microns.

[0015] The matrix wrapper can have a uniform thickness that does not vary by more than about 30 microns, or more than about 20 microns, or more than about 10 microns, or more than about 5 microns, or more than about 2 microns at any point.

[0016] The ratio of substrate wrapper thickness to aerosol-forming substrate portion diameter may range from about 1:120 to about 1:20, or from about 1:100 to about 1:30, or from about 1:80 to about 1:35, or from about 1:60 to about 1:40.

[0017] The angle between the first straight line and the second straight line may be between 0 and 20 degrees, preferably between 0 and 15 degrees, more preferably between 0 and 10 degrees, and more preferably between 0 and 5 degrees.

[0018] The region of overlap may extend along less than 20%, preferably less than 15%, more preferably less than 10%, more preferably less than 5% of the circumference of the aerosol-forming substrate portion.

[0019] A second straight line may be defined as extending from the central axis to the middle of the overlapping area. "Middle of the overlapping area" refers to the centre of the overlapping area along the circumference of the aerosol-generating article perpendicular to the central axis.

[0020] A second straight line may be defined as extending from the central axis to a glue area or glue line provided in the overlap region.

[0021] The thickness of the substrate wrapper may be measured in areas that are not overlap areas.

[0022] The susceptor may be a flat planar susceptor strip. The flat planar susceptor strip may be elongated in a direction parallel to the central axis. The susceptor may have a length of 5 mm to 15 mm, preferably 9 mm to 13 mm, and a width of at least about 1 mm, preferably at least about 2 mm.

[0023] The susceptor may be arranged centrally within the aerosol-forming substrate portion.

[0024] The length of the overlap region may be equal to or greater than the length of the susceptor in a direction parallel to the central axis. The width of the overlap region may be equal to or less than the width of the susceptor in a direction perpendicular to the central axis and parallel to the planar plane of the planar susceptor portion.

[0025] The susceptor may comprise a metallic material, preferably aluminium.

[0026] The matrix packaging material can have 800 kg / m3 or less density. The density of the matrix packaging material can be 750 kg / m3 or less, preferably 700 kg / m3 or less, more preferably 650 kg / m3 or less, more preferably 600 kg / m3 or less, more preferably 550 kg / m3 or less, more preferably 500 kg / m3 or less, more preferably 450 kg / m3 or less. The density of the matrix packaging material can be 400 kg / m3 or less, preferably 350 kg / m3 or less, more preferably about 320 kg / m3.

[0027] The density of substrate packaging material can be 400 kilograms / cubic metre or lower, and the thickness that substrate packaging material can have is 60 microns or larger, preferably 70 microns or larger, more preferably 75 microns or larger, more preferably 80 microns or larger, more preferably 90 microns or larger, more preferably 100 microns or larger, more preferably 110 microns or larger, more preferably 120 microns or larger, more preferably 130 microns or larger, more preferably 140 microns or larger, more preferably 145 microns or larger, more preferably 150 microns or larger.The substrate packaging material can have the thickness of approximately 148 microns.The density of substrate packaging material can be 400 kilograms / cubic metre or less, and the thickness of substrate packaging material can be between 143 microns and 153 microns.The density of substrate packaging material can be 400 kilograms / cubic metre or less, and the thickness of substrate packaging material can be between 140 microns and 160 microns.

[0028] The basis weight of the substrate packaging material may be less than 60 grams per square meter. The basis weight of the substrate packaging material may be greater than 28 grams per square meter and less than 60 grams per square meter. The basis weight of the substrate packaging material may be greater than 45 grams per square meter and less than 60 grams per square meter.

[0029] The basis weight of the substrate packaging material may be less than 50 grams per square meter. The basis weight of the substrate packaging material may be greater than 28 grams per square meter and less than 50 grams per square meter. The basis weight of the substrate packaging material may be greater than 45 grams per square meter and less than 50 grams per square meter. The basis weight of the substrate packaging material may be about 48 grams per square meter.

[0030] The substrate wrapper may have a thickness greater than 145 microns, and a density of 400 kg / m3 or less.

[0031] The matrix wrapper may include one or more perforations or may not include any perforations.

[0032] The matrix wrapper may exhibit a permeability of the wrapper of more than 10 CORESTA units, more than 20 CORESTA units, more than 50 CORESTA units, more than 100 CORESTA units, more than 500 CORESTA units, more than 1000 CORESTA units, more than 1500 CORESTA units, more than 2000 CORESTA units, more than 2500 CORESTA units, more than 3000 CORESTA units, more than 3500 CORESTA units or more than 4000 CORESTA units. The matrix wrapper may exhibit a permeability of the wrapper of between 10 CORESTA units and 10,000 CORESTA units, preferably between 50 CORESTA units and 8000 CORESTA units, more preferably between 100 CORESTA units and 5000 CORESTA units. The matrix wrapper may exhibit a wrapper permeability of between 4000 and 4800 CORESTA Units, preferably between 4200 and 4600 CORESTA Units, more preferably between 4300 and 4500 CORESTA Units.

[0033] The matrix wrapper may have a thickness greater than 145 microns, a density of 400 kg / m3 or less, and a wrapper permeability between 50 and 5000 CORESTA units, preferably between 4200 and 4600 CORESTA units, more preferably between 4300 and 4500 CORESTA units.

[0034] The permeability of a substrate wrapper may be determined using the international standard test method ISO 2965:2009, and the results may be expressed in cubic centimeters per minute per square centimeter and are referred to as "CORESTA units."

[0035] Aerosol generating articles can include additional packaging materials that limit substrate packaging materials. Additional packaging materials can show that the permeability of packaging materials is less than 100 CORESTA units, less than 80 CORESTA units, less than 50 CORESTA units, less than 40 CORESTA units or less than 30 CORESTA units. The permeability of additional packaging materials can be less than the permeability of substrate packaging materials. The permeability of additional packaging materials can be less than 1%, less than 2%, less than 5%, less than 10% or less than 20% of the permeability of substrate packaging materials. The permeability of additional packaging materials can be less than 50 CORESTA units, and the permeability of substrate packaging materials can be between 4000CORESTA units and 4800 CORESTA units, preferably between 4200 CORESTA units and 4600 CORESTA units, more preferably between 4300 CORESTA units and 4500 CORESTA units. Additional packaging materials can be tipping packaging materials as described herein. Additional packaging materials can be combination packaging materials. Additional packaging materials can advantageously reduce the overall permeability of substrate packaging materials with high permeability.

[0036] The matrix wrapper may be convex or non-convex.The matrix wrapper may be both perforated and convex.

[0037] The term "protrusion" is used herein to refer to a protrusion formed in the surface of a package. These protrusions may be engraved, molded or embossed into the package. The portion of the package carrying such a protrusion is referred to as raised.

[0038] The matrix packaging material can include a projection. The projection of the matrix packaging material can have a projection. The projection of the matrix packaging material can have a plurality of projections. One or more projections can have a depth of 0.07 to 0.21 millimeter, preferably 0.10 to 0.18 millimeter, more preferably 0.12 to 0.16 millimeter. The spacing of each projection can also be 0.2 to 0.4 millimeter, preferably 0.25 to 0.35 millimeter, more preferably 0.275 to 0.325 millimeter.

[0039] The roughness of the substrate wrapper can be between about 50 Bekk seconds and about 1000 Bekk seconds, preferably between about 100 Bekk seconds and about 200 Bekk seconds. The roughness expressed in Bekk seconds can be measured by means of a standard test using a BEKK smoothness tester, which creates a vacuum and measures the time it takes for the vacuum to drop from 50.66 kPa to 48.00 kPa. This test is recognized by the international standard ISO 5627.

[0040] As used herein, "total density of the aerosol-forming substrate portion" refers to the total mass of material received within the volume defined by the substrate wrapper divided by the volume defined by the substrate wrapper. The mass of the substrate wrapper itself and optional other wrappers defining the substrate wrapper are not taken into account. The volume of the substrate wrapper itself and optional other wrappers defining the substrate wrapper are not taken into account.

[0041] The total density of the aerosol-forming substrate portion can be determined after conditioning the aerosol-generating article according to ISO standard 3402:1999. The aerosol-forming substrate is removed from the aerosol-forming substrate portion and weighed. The receptor is also removed from the aerosol-forming substrate portion and also weighed. The internal volume of the aerosol-forming substrate portion is determined. This can be done, for example, by laser measurement. The internal volume of the aerosol-forming substrate portion corresponds roughly to the cylindrical volume within the substrate packaging. The total density of the aerosol-forming substrate portion is calculated by dividing the sum of the mass of the aerosol-forming substrate and the mass of the receptor by the internal volume of the substrate portion. For 20 different individual aerosol-generating articles, this can be repeated 20 times to receive an average value.

[0042] As used herein, the "total density of the aerosol-generating article at a longitudinal position of the aerosol-forming substrate portion" refers to the total mass of material received within the volume defined by the average cross-sectional area of ​​the aerosol-forming substrate portion along the length of the aerosol-forming substrate portion of the aerosol-generating article divided by the volume. The mass of each of the aerosol-forming substrate, the susceptor, the substrate wrapper, and each of the one or more optional additional wrappers defining the substrate wrapper is taken into account. The volume of the substrate wrapper itself and each of the one or more optional additional wrappers defining the substrate wrapper is taken into account.

[0043] The overall density of an aerosol-generating article at a longitudinal position of the aerosol-forming substrate portion may be determined after conditioning the aerosol-generating article according to ISO standard 3402:1999.

[0044] The thickness of the matrix wrapper can be determined according to ISO 534:2011. The density of the matrix wrapper can be determined according to ISO 534:2011. The thickness of the matrix wrapper can be determined according to ASTM E252-06 (2021) e1. Generally, for a raised matrix wrapper, the local thickness at the location of the raised portion can be less than the thickness at a location without the raised portion. As used herein, for a raised wrapper, the thickness of the matrix wrapper refers to the thickness at a location without the raised portion. For a raised wrapper, the thickness of the matrix wrapper can be determined before the wrapper is raised.

[0045] Unless otherwise defined, all measurements described herein were performed after conditioning the samples according to ISO Standard 3402:1999.

[0046] The density of the substrate wrapper can be calculated by dividing the basis weight of the substrate wrapper by the thickness of the substrate wrapper. Basis weight, also known as gram weight, refers to the mass of the substrate wrapper per sheet size, usually expressed in grams per square meter. Basis weight can be obtained, for example, by weighing a 1 square meter sheet of substrate wrapper.

[0047] As used herein, the term "lightweight" when referring to the substrate packaging material means that the density of the substrate packaging material is 800 kg / m3 or less, preferably 750 kg / m3 or less, more preferably 700 kg / m3 or less, more preferably 650 kg / m3 or less, more preferably 600 kg / m3 or less, more preferably 550 kg / m3 or less, more preferably 500 kg / m3 or less, more preferably 450 kg / m3 or less, more preferably 400 kg / m3 or less, more preferably 350 kg / m3 or less, more preferably about 320 kg / m3.

[0048] As used herein, the term "thick" when referring to a substrate package means that the thickness of the substrate package is 50 microns or greater, preferably 60 microns or greater, more preferably 70 microns or greater, more preferably 75 microns or greater, more preferably 80 microns or greater, more preferably 90 microns or greater, more preferably 100 microns or greater, more preferably 110 microns or greater, more preferably 120 microns or greater, more preferably 130 microns or greater, more preferably 140 microns or greater, more preferably 145 microns or greater, more preferably 150 microns or greater.

[0049] The substrate wrapper may extend along the entire length of the aerosol-forming substrate portion in a direction along the longitudinal axis of the aerosol-generating article. The substrate wrapper may extend along at least 40%, preferably at least 50%, more preferably at least 60%, more preferably at least 70%, more preferably at least 80%, more preferably at least 90%, more preferably at least 95% of the length of the aerosol-forming substrate portion in a direction along the longitudinal axis of the aerosol-generating article.

[0050] The substrate wrapper may be in direct physical contact with the aerosol-forming substrate. In this case, there is no material layer between the substrate wrapper and the aerosol-forming substrate.

[0051] The substrate wrapper may be formed from a single continuous sheet of material. The single continuous sheet may wrap about one turn around the aerosol-forming substrate portion. Generally, the single continuous sheet may wrap slightly more than one turn around the substrate portion to form an overlapping region of the opposite end portions of the substrate wrapper. The thickness of the wrapper should not be measured in the overlapping region. Therefore, except for the optional overlapping region (if present), the substrate wrapper formed from a single continuous sheet of material may only include a single layer.

[0052] The substrate wrapper may be formed by a single continuous sheet that is wrapped around the aerosol-forming substrate portion for at least about two or more turns. In this case, two or more layers of substrate wrapper are wrapped around the aerosol-forming substrate portion without taking into account the additional overlapping area formed by the overlapping opposite end portions of the wrapper. In this case, the thickness of the substrate wrapper can be obtained by multiplying the thickness of the individual layers, i.e. the sheet thickness, by the number of turns. The thickness of the substrate wrapper is not obtained by multiplying the thickness of the individual layers by the number of turns in the overlapping area formed by the overlapping opposite end portions of the wrapper. None of the individual layers extend beyond the end of the aerosol-forming substrate portion in the longitudinal direction of the aerosol-generating article.

[0053] The substrate wrapper may comprise one or more of paperboard, plastic, and metal foil.

[0054] The substrate wrapper may comprise a cellulosic material, such as one or more of paper, wood, textiles, natural fibers and man-made fibers. The substrate wrapper may comprise a paper layer. The substrate wrapper may be made of a single paper sheet. In addition to the optional overlapping portion, the substrate wrapper may comprise a single paper layer wrapped around the aerosol-forming substrate portion. The substrate wrapper may be made of a single paper sheet wrapped twice or more around the aerosol-forming substrate portion, thereby producing a substrate wrapper comprising two or more layers with the same length.

[0055] The substrate wrapper may be a paper wrapper or a non-paper wrapper. Suitable non-paper wrappers include, but are not limited to, sheets of homogenised tobacco material.

[0056] The substrate wrapper may comprise a laminate. The substrate wrapper may be made from a single laminate. The laminate may be a laminate of a paper layer and an aluminium layer.

[0057] The packaging material may be formed from a laminate comprising a plurality of layers. The packaging material may be formed from a metal co-laminated sheet, such as an aluminum co-laminated sheet. The metal layer of the co-laminated sheet may have a grammage of 12 g / m2 to 25 g / m2, preferably 15 g / m2 to 20 g / m2. The thickness of the metal layer of the co-laminated sheet may be 2 μm to 15 μm, preferably 3 μm to 12 μm, more preferably 5 μm to 10 μm.

[0058] The base packaging material may be a paper packaging material including PVOH (polyvinyl alcohol) or silicone (or polysiloxane) (or polysiloxane). Adding PVOH (polyvinyl alcohol) or silicone (or polysiloxane) can improve the grease barrier properties of the packaging material.

[0059] The substrate wrapper may include a flame retardant composition including one or more flame retardant compounds. The term "flame retardant compound" is used herein to describe compounds that, when added to or otherwise incorporated into a carrier substrate (e.g., paper or plastic compound), provide varying degrees of flammability protection to the carrier substrate.

[0060] Many suitable flame retardant compounds are known to the skilled person. In particular, several flame retardant compounds and formulations suitable for treating cellulosic materials are known and have been disclosed and can be used in the manufacture of packaging for aerosol-generating articles according to the present invention.

[0061] The substrate wrapper may be a substrate wrapper system formed by two or more separate substrate wrapper sub-sheets. In this case, the thickness of the substrate wrapper may be obtained by adding the thicknesses of the separate substrate wrapper sub-sheets of the substrate wrapper system. It is possible that no separate substrate wrapper sub-sheet extends beyond the end of the aerosol-forming substrate portion in the longitudinal direction of the aerosol-generating article. Each of the separate substrate wrapper sub-sheets forming the substrate wrapper system may have the same length in a direction parallel to the longitudinal axis of the aerosol-generating article.

[0062] The substrate packaging can be a substrate packaging system formed by two or more separate substrate packaging sub-sheets, wherein each of the two or more separate substrate packaging sub-sheets at least partially defines the aerosol-forming substrate portion, wherein none of the two or more separate substrate packaging sub-sheets extends beyond the end of the aerosol-forming substrate portion in the longitudinal direction of the aerosol generating article, wherein each of the two or more separate substrate packaging sub-sheets has a thickness of 50 microns or greater and a density of 800 kg / m3 or less, and preferably, wherein each of the separate substrate packaging sub-sheets forming the substrate packaging system has the same length in a direction parallel to the longitudinal axis of the aerosol generating article.

[0063] The substrate wrapper can be a substrate wrapper system formed by two or more separate substrate wrapper sub-sheets, wherein each of the two or more separate substrate wrapper sub-sheets at least partially defines the aerosol-forming substrate portion, wherein each of the two or more separate substrate wrapper sub-sheets has the same length in the longitudinal direction of the aerosol generating article, and wherein each of the two or more separate substrate wrapper sub-sheets has a thickness of 50 microns or greater and a density of 800 kg / m3 or less.

[0064] The substrate packaging can be a substrate packaging system formed by two or more separate substrate packaging sub-sheets, wherein each of the two or more separate substrate packaging sub-sheets at least partially defines the aerosol-forming substrate portion, wherein none of the two or more separate substrate packaging sub-sheets extends beyond the end of the aerosol-forming substrate portion in the longitudinal direction of the aerosol generating article, wherein the sum of the two or more separate substrate packaging sub-sheets has a thickness of 50 microns or greater and a density of 800 kg / m3 or less, and preferably, wherein each of the separate substrate packaging sub-sheets forming the substrate packaging system has the same length in a direction parallel to the longitudinal axis of the aerosol generating article.

[0065] The substrate wrapper can be a substrate wrapper system formed by two or more separate substrate wrapper sub-sheets, wherein each of the two or more separate substrate wrapper sub-sheets at least partially defines the aerosol-forming substrate portion, wherein each of the two or more separate substrate wrapper sub-sheets has the same length in the longitudinal direction of the aerosol generating article, and wherein the sum of the two or more separate substrate wrapper sub-sheets has a thickness of 50 microns or greater and a density of 800 kg / m3 or less.

[0066] The matrix packaging system can be formed by two independent sheets. The matrix packaging system can be formed by a first independent sheet and a second independent sheet. The first independent sheet can be provided by the first package, and the first package includes a first overlapping area formed by the overlapping of the opposite end portions of the first package. The second independent sheet can be provided by the second package, and the second package includes a second overlapping area formed by the overlapping of the opposite end portions of the second package. The first overlapping area can be offset from the second overlapping area to form at least about 5% of the circumference of the aerosol-forming matrix part, preferably at least about 10% of the circumference of the aerosol-forming matrix part, more preferably at least about 15% of the circumference of the aerosol-forming matrix part, more preferably about 40% to about 60% of the circumference of the aerosol-forming matrix part. The first overlapping area can be offset from the second overlapping area to form about 50% of the circumference of the aerosol-forming matrix part. The first overlapping area and the second overlapping area are arranged on the opposite sides of the flat plane susceptor part. One or both of the first independent sheet and the second independent sheet can be a paper packaging material.

[0067] The aerosol-generating article may include a downstream section positioned downstream of the aerosol-forming substrate portion. The downstream section is preferably positioned immediately downstream of the aerosol-forming substrate portion. The downstream section of the aerosol-generating article preferably extends between the aerosol-forming substrate portion and the downstream end of the aerosol-generating article. The downstream section may include one or more elements, each of which will be described in more detail within the present disclosure.

[0068] The length of the downstream section may be at least 10 mm, or at least 20 mm, or at least 25 mm, or at least 30 mm.

[0069] The length of the downstream section may be less than 70 mm, or less than 60 mm, or less than 50 mm.

[0070] For example, the length of the downstream section may be between 20 and 70 mm, or between 25 and 60 mm, or between 30 and 50 mm.

[0071] The downstream section of an aerosol-generating article according to the invention preferably comprises a hollow tubular cooling element disposed downstream of the aerosol-forming substrate portion.The hollow tubular cooling element may advantageously provide an aerosol-cooling element for the aerosol-generating article.

[0072] The hollow tubular cooling element may be arranged immediately downstream of the aerosol-forming substrate portion. In other words, the hollow tubular cooling element may be adjacent to the downstream end of the aerosol-forming substrate portion. The hollow tubular cooling element may define the upstream end of the downstream section of the aerosol-generating article. The downstream end of the aerosol-generating article may coincide with the downstream end of the downstream section. In some embodiments, the downstream section of the aerosol-generating article comprises a single hollow tubular element. In other words, the downstream section of the aerosol-generating article may include only one hollow tubular element. In other embodiments, as described below, the downstream section comprises two or more hollow tubular elements.

[0073] As used throughout this disclosure, the term "hollow tubular element" refers to a generally elongated element that defines a lumen or airflow passage along its longitudinal axis. In particular, the term "tubular" will hereinafter be used to refer to a tubular element having a substantially cylindrical cross-section and defining at least one airflow conduit that establishes uninterrupted fluid communication between an upstream end of the tubular element and a downstream end of the tubular element. However, it should be understood that alternative geometries of the tubular element (e.g., alternative cross-sectional shapes) may be possible. The hollow tubular cooling element may be a single discrete element of the aerosol-generating article having a defined length and thickness.

[0074] In the context of the present invention, the hollow tubular cooling element provides an unrestricted flow channel. This means that the hollow tubular cooling element provides a negligible resistance to draw (RTD) level. The term "negligible RTD level" is used to describe an RTD of less than 1 mm H2O / 10 mm length of the hollow tubular cooling element, preferably less than 0.4 mm H2O / 10 mm length of the hollow tubular cooling element, more preferably less than 0.1 mm H2O / 10 mm length of the hollow tubular cooling element.

[0075] The RTD of the hollow tubular cooling element is preferably less than or equal to 10 mmH2O, or less than or equal to 5 mmH2O, or less than or equal to 2.5 mmH2O, or less than or equal to 2 mmH2O, or less than or equal to 1 mmH2O.

[0076] The RTD of the hollow tubular cooling element may be at least 0 mmH2O, or at least 0.25 mmH2O, or at least 0.5 mmH2O, or at least 1 mmH2O.

[0077] In an aerosol-generating article according to the invention, the overall RTD of the article depends substantially on the RTD of the strip and optionally on the RTD of downstream and / or upstream elements. This is because the hollow tubular cooling element is substantially empty and thus substantially only minimally affects the overall RTD of the aerosol-generating article.

[0078] Therefore, the flow channel should be free of any components that would hinder the flow of air in the longitudinal direction.Preferably, the flow channel is substantially empty, and particularly preferably the flow channel is empty.

[0079] As will be described in more detail within the present disclosure, the aerosol-generating article may include a ventilation zone at a location along the downstream segment. In some embodiments, the aerosol-generating article may include a ventilation zone at a location along the hollow tubular cooling element. This ventilation zone or any ventilation zone may extend through the peripheral wall of the hollow tubular cooling element. Thus, fluid communication is established between the flow channel defined by the interior of the hollow tubular cooling element and the external environment. Ventilation zones are further described within the present disclosure.

[0080] The length of the hollow tubular cooling element may be at least 15 mm, or at least 20 mm, or at least 25 mm. The length of the hollow tubular cooling element may be less than 50 mm, or less than 45 mm, or less than 40 mm. For example, the length of the hollow tubular cooling element may be between 15 mm and 50 mm, or between 20 mm and 45 mm, or between 20 mm and 40 mm, or between 20 mm and 30 mm, or between 25 mm and 40 mm.

[0081] The relatively long hollow tubular cooling element provides and defines a relatively long internal cavity within the aerosol-generating article and downstream of the aerosol-forming substrate portion. Providing a cavity downstream (preferably, immediately downstream) of the aerosol-forming substrate enhances nucleation of aerosol particles generated by the substrate. Providing a relatively long cavity maximizes such nucleation benefits, thereby improving aerosol formation and cooling.

[0082] The wall thickness of the hollow tubular cooling element may be between 100 microns and 2 millimeters, or between 150 microns and 1.5 millimeters, or between 200 microns and 1.25 millimeters.

[0083] The outer diameter of the hollow tubular cooling element is preferably substantially equal to the outer diameter of the aerosol-generating article.

[0084] The hollow tubular cooling element may have an outer diameter between 5 mm and 10 mm, for example between 5.5 mm and 9 mm or between 6 mm and 8 mm. In some embodiments, the hollow tubular cooling element has an outer diameter of less than 7 mm.

[0085] The hollow tubular cooling element may have an inner diameter. Preferably, the hollow tubular cooling element has a constant inner diameter along the length of the hollow tubular cooling element. However, the inner diameter of the hollow tubular cooling element may vary along the length of the hollow tubular cooling element.

[0086] The hollow tubular cooling element may have an inner diameter of at least 2 mm. For example, the hollow tubular cooling element may have an inner diameter of at least 3 mm, at least 4 mm, or at least 5 mm.

[0087] Providing a hollow tubular cooling element having an inner diameter as described above may advantageously provide the hollow tubular cooling element with sufficient rigidity and strength.

[0088] The hollow tubular cooling element may have an inner diameter of no more than 10 mm. For example, the hollow tubular cooling element may have an inner diameter of no more than 9 mm, no more than 8 mm, or no more than 7 mm.

[0089] Providing a hollow tubular cooling element having an inner diameter as described above may advantageously reduce the pumping resistance of the hollow tubular cooling element.

[0090] The hollow tubular cooling element may have an inner diameter of between 2 mm and 10 mm, between 3 mm and 9 mm, between 4 mm and 8 mm, or between 5 mm and 7 mm.

[0091] The lumen or cavity of the hollow tubular cooling element may have any cross-sectional shape. The lumen of the hollow tubular cooling element may have a circular cross-sectional shape.

[0092] The hollow tubular cooling element may comprise a paper based material. The hollow tubular cooling element may comprise at least one paper layer. The paper may be a very rigid paper. The paper may be a curled paper, such as a curled heat resistant paper or a curled parchment paper.

[0093] Preferably, the hollow tubular cooling element may comprise paperboard. The hollow tubular cooling element may be a paperboard tube. The hollow tubular cooling element may be formed from paperboard. Advantageously, paperboard is a cost-effective material that provides a balance between being deformable to provide ease of insertion of the article into the aerosol generating device and being sufficiently rigid to provide appropriate engagement of the article with the interior of the device. Thus, the paperboard tube may provide suitable resistance to deformation or compression during use.

[0094] The hollow tubular cooling element may be a paper tube. The hollow tubular cooling element may be a tube formed from spirally wound paper. The hollow tubular cooling element may be formed from a plurality of paper layers. The paper may have a basis weight of at least 50 g / m2, at least 60 g / m2, at least 70 g / m2 or at least 90 g / m2.

[0095] The hollow tubular cooling element may comprise a polymeric material. For example, the hollow tubular cooling element may comprise a polymer film. The polymer film may comprise a cellulose film. The hollow tubular cooling element may comprise low density polyethylene (LDPE) or polyhydroxyalkanoate (PHA) fibers. The hollow tube may comprise cellulose acetate tow.

[0096] Where the hollow tubular cooling element comprises cellulose acetate tow, the cellulose acetate tow may have a denier per filament between 2 and 4 and a total denier between 25 and 40.

[0097] Preferably, aerosol-generating articles according to the invention comprise a ventilation zone located at a position along the downstream segment. In more detail, in those embodiments in which the downstream segment comprises a hollow tubular cooling element, the ventilation zone may be provided at a position along the hollow tubular cooling element. Alternatively or additionally, in those embodiments in which the downstream segment comprises a downstream hollow tubular element, as described below, the ventilation zone may be provided at a position along the downstream hollow tubular element.

[0098] Thus, the ventilation chamber is arranged downstream of the aerosol-forming substrate portion. This provides several potential technical benefits. Firstly, the inventors have found that one such ventilated hollow tubular cooling element provides particularly effective aerosol cooling. Secondly, the inventors unexpectedly found that such rapid cooling of the volatile substances released when heating the aerosol-forming substrate enhances the nucleation of aerosol particles.

[0099] The ventilation zone may typically comprise a plurality of perforations through the peripheral wall of the hollow tubular cooling element. Preferably, the ventilation zone comprises at least one row of circumferential perforations. In some embodiments, the ventilation zone may comprise two rows of circumferential perforations. For example, the perforations may be formed on a production line during manufacture of the aerosol-generating article. Preferably, each row of circumferential perforations comprises 8 to 30 perforations.

[0100] Aerosol-generating articles according to the invention may have a ventilation level of at least 40%. Increasing the ventilation level may increase the level of aerosol cooling. However, increasing the ventilation level may mean that less air enters the aerosol-generating article via the upstream end of the aerosol-generating article, which then flows through the aerosol-forming substrate portion. The ventilation level may thus be selected based on the desired temperature and composition of the aerosol delivered to the user.

[0101] The aerosol-generating article preferably has a ventilation level of at least 45%, more preferably at least 50%, more preferably at least 60%, more preferably at least 70%.

[0102] Aerosol-generating articles according to the invention may have a ventilation level of less than or equal to 90%, more preferably less than or equal to 85%, more preferably less than or equal to 80%.

[0103] Thus, the aerosol-generating article according to the present invention may have a ventilation level of 45% to 90%, more preferably 45% to 85%, even more preferably 45% to 80%. The aerosol-generating article according to the present invention may have a ventilation level of 50% to 90%, preferably 50% to 85%, more preferably 50% to 80%. The aerosol-generating article according to the present invention may have a ventilation level of 60% to 90%, preferably 60% to 85%, more preferably 60% to 80%. The aerosol-generating article according to the present invention may have a ventilation level of 70% to 90%, preferably 70% to 85%, more preferably 70% to 80%.

[0104] For example, the aerosol-generating article may have a ventilation level of about 75%.

[0105] As discussed in the present disclosure, the downstream segment may include a downstream filter segment. The downstream filter segment may extend to the downstream end of the downstream segment. The downstream filter segment may be positioned at the downstream end of the aerosol generating article. The downstream end of the downstream filter segment may define the downstream end of the aerosol generating article. The downstream filter segment may also be referred to as a mouth-end filter.

[0106] The downstream filter segment may be positioned downstream of the hollow tubular cooling element as described above.The downstream filter segment may extend between the hollow tubular cooling element and the downstream end of the aerosol-generating article.

[0107] The downstream filter segment is preferably a solid rod, which may also be described as a "plain" rod and is non-tubular. Thus, the filter segment preferably has a substantially uniform cross-section.

[0108] The downstream filter segment is preferably formed of a fibrous filter material. The fibrous filter material may be used to filter the aerosol generated by the aerosol-forming substrate. Suitable fibrous filter materials will be known to the skilled person. Particularly preferably, at least one downstream filter segment comprises a cellulose acetate filter segment formed of cellulose acetate tow.

[0109] In certain preferred embodiments, the downstream section comprises a single downstream filter segment.In alternative embodiments, the downstream section comprises two or more downstream filter segments axially aligned in end-to-end abutting relationship with each other.

[0110] The downstream filter segment may optionally include a flavoring agent, which may be provided in any suitable form. For example, the downstream filter segment may include one or more capsules, beads or particles of a flavoring agent, or one or more threads or wires loaded with a flavoring agent.

[0111] Preferably, the downstream filter segment has a low particle filtration efficiency.

[0112] Preferably, the downstream filter segment is defined by the stick wrap.Preferably, the downstream filter segment is not ventilated, such that air does not enter the aerosol-generating article along the downstream filter segment.

[0113] The downstream filter segment is preferably connected to one or more of the adjacent upstream components of the aerosol-generating article by means of a tipping wrapper.

[0114] The downstream filter segment preferably has an outer diameter substantially equal to the outer diameter of the aerosol-generating article.The outer diameter of the downstream filter segment may be substantially the same as the outer diameter of the hollow tubular cooling element.

[0115] The outer diameter of the downstream filter segment may be between 5 mm and 10 mm, or between 5.5 mm and 9 mm, or between 6 mm and 8 mm. In certain embodiments, the outer diameter of the downstream filter segment is less than 7 mm.

[0116] Unless otherwise stated, the resistance to draw (RTD) of a component or aerosol generating article is measured in accordance with ISO 6565-2015. RTD refers to the pressure required to force air through the full length of the component. The term "pressure drop" or "draw resistance" of a component or article may also refer to "resistance to draw". Such terms generally refer to measurements in accordance with ISO 6565-2015, generally at a temperature of 22 degrees Celsius, a pressure of 101 kPa (about 760 Torr) and a relative humidity of 60%, at a volume flow rate of 17.5 ml / sec at the output or downstream end of the measuring component. Conditions for smoking and smoking machine specifications are set forth in ISO Standard 3308 (ISO 3308:2000). Conditioning and testing atmospheres are set forth in ISO Standard 3402 (ISO 3402:1999).

[0117] The resistance to suction (RTD) can be expressed in the pressure unit "millimeters of water column" (mmWG).

[0118] The downstream section may have a resistance to draw (RTD) of at least 0 mmH2O. The downstream section may have an RTD of at least 3 mmH2O. The downstream section may have an RTD of at least 6 mmH2O. The downstream section may have an RTD of no more than 12 mmH2O. The downstream section may have an RTD of no more than 11 mmH2O. The downstream section may have an RTD of no more than 10 mmH2O.

[0119] The resistance to draw (RTD) characteristics of the downstream segment may be entirely or primarily attributable to the RTD characteristics of the downstream filter segment of the downstream segment. In other words, the RTD of the downstream filter segment of the downstream segment may entirely define the RTD of the downstream segment.

[0120] The downstream filter segment may have a resistance to draw (RTD) of at least 0 mmH2O, or at least 3 mmH2O, or at least 6 mmH2O. The downstream filter segment may have an RTD of no greater than 12 mmH2O, or no greater than 11 mmH2O, or no greater than 10 mmH2O.

[0121] As described above, the downstream filter segment can be formed of a fibrous filter material. The downstream filter segment can be formed of a porous material. The downstream filter segment can be formed of a biodegradable material. The downstream filter segment can be formed of a cellulosic material such as cellulose acetate. For example, the downstream filter segment can be formed of bundled cellulose acetate fibers having a single filament denier between 10 and 15. For example, the downstream filter segment is formed of a relatively low density cellulose acetate tow (such as a cellulose acetate tow comprising fibers having a single filament denier of 12).

[0122] The downstream filter segment can be formed by a material based on polylactic acid. The downstream filter segment can be formed by a bioplastic material (preferably a starch-based bioplastic material). The downstream filter segment can be made by injection molding or by extrusion. Bioplastic-based materials are advantageous because they can provide a downstream filter segment structure that is simple and inexpensive to manufacture, has a specific and complex cross-sectional profile, and can include a plurality of relatively large airflow channels extending through the downstream filter segment material, which provides suitable RTD characteristics.

[0123] The length of the downstream filter segment can be at least 5 mm, or at least 10 mm. The length of the downstream filter segment can be less than 25 mm, or less than 20 mm. For example, the length of the downstream filter segment can be between 5 mm and 25 mm, or between 10 mm and 25 mm, or between 5 mm and 20 mm, or between 10 mm and 20 mm.

[0124] The downstream section may also include one or more additional hollow tubular elements.

[0125] In certain embodiments, the downstream section may comprise a hollow tubular support element upstream of the hollow tubular cooling element described above. Preferably, the hollow tubular support element abuts the downstream end of the aerosol-forming substrate portion. Preferably, the hollow tubular support element abuts the upstream end of the hollow tubular cooling element. Preferably, the hollow tubular support element and the hollow tubular cooling element are adjacent to each other and together provide a hollow tubular section within the downstream section.

[0126] The hollow tubular support element may be formed from any suitable material or combination of materials. For example, the support element may be formed from one or more materials selected from the group consisting of: cellulose acetate; paperboard; curled paper, such as curled heat resistant paper or curled parchment paper; and polymeric materials, such as low density polyethylene (LDPE). In a preferred embodiment, the support element is formed from cellulose acetate. Other suitable materials include polyhydroxyalkanoate (PHA) fibers. In a preferred embodiment, the hollow tubular support element comprises a hollow acetate tube.

[0127] The outer diameter of the hollow tubular support element is preferably substantially equal to the outer diameter of the aerosol-generating article.

[0128] The hollow tubular support element may have an outer diameter between 5 mm and 10 mm, for example between 5.5 mm and 9 mm or between 6 mm and 8 mm. In a preferred embodiment, the hollow tubular support element has an outer diameter of less than 7 mm.

[0129] The hollow tubular support element may have a wall thickness of at least 1 mm, preferably at least 1.5 mm, more preferably at least 2 mm.

[0130] The hollow tubular support element may have a length of at least 5 mm. Preferably, the support element has a length of at least 6 mm, more preferably at least 7 mm.

[0131] The hollow tubular support element may have a length of less than 15 mm. Preferably, the hollow tubular support element has a length of less than 12 mm, more preferably less than 10 mm.

[0132] In some embodiments, the hollow tubular support element has a length of 5 mm to 15 mm, preferably 6 mm to 15 mm, more preferably 7 mm to 15 mm. In other embodiments, the hollow tubular support element has a length of 5 mm to 12 mm, preferably 6 mm to 12 mm, more preferably 7 mm to 12 mm. In other embodiments, the support element has a length of 5 mm to 10 mm, preferably 6 mm to 10 mm, more preferably 7 mm to 10 mm.

[0133] Alternatively or in addition to the hollow tubular support element, the downstream section may also include a downstream hollow tubular element downstream of the hollow tubular cooling element. The downstream hollow tubular element may be arranged in close proximity to the hollow tubular cooling element. Alternatively or preferably, the downstream hollow tubular element is separated from the hollow tubular cooling element by at least one other component. For example, the downstream section may include a downstream filter segment between the hollow tubular cooling element and the downstream hollow tubular element.

[0134] Preferably, the downstream hollow tubular element extends to the downstream end of the downstream section. Thus, the downstream hollow tubular element preferably extends to the downstream end of the aerosol-generating article. In the case where the downstream hollow tubular element extends to the downstream end of the aerosol-generating article, the downstream hollow tubular element may define the mouth end cavity of the aerosol-generating article.

[0135] In certain embodiments, additional downstream hollow tubular elements may be provided such that the downstream section includes two adjacent downstream hollow tubular elements downstream of the downstream filter segment.

[0136] The RTD of the downstream hollow tubular element can be less than or equal to 10 mmHg, or less than or equal to 5 mmHg, or less than or equal to 2.5 mmHg, or less than or equal to 2 mmHg. Preferably, the RTD of the downstream hollow tubular element is less than or equal to 1 mmHg. The RTD of the downstream hollow tubular element can be at least 0 mmHg, or at least 0.25 mmHg, or at least 0.5 mmHg, or at least 1 mmHg.

[0137] Therefore, the flow channel of the downstream hollow tubular element should be free of any components that would hinder the flow of air in the longitudinal direction.Preferably, the flow channel is substantially empty, and particularly preferably the flow channel is empty.

[0138] Preferably, the length of the downstream hollow tubular element is at least 3 mm, more preferably at least 4 mm, more preferably at least 5 mm, more preferably at least 6 mm. The length of the downstream hollow tubular element is preferably less than 20 mm, more preferably less than 15 mm, more preferably less than 12 mm, more preferably less than 10 mm.

[0139] The lumen or cavity of the downstream hollow tubular element may have any cross-sectional shape.The lumen of the downstream hollow tubular element may have a circular cross-sectional shape.

[0140] The downstream hollow tubular element may comprise a paper-based material. The downstream hollow tubular element may comprise at least one paper layer. The paper may be a very rigid paper. The paper may be a curled paper, such as a curled heat-resistant paper or a curled parchment paper. The downstream hollow tubular element may comprise a cardboard. The downstream hollow tubular element may be a cardboard tube.

[0141] The downstream hollow tubular element may be a paper tube. The downstream hollow tubular element may be a tube formed by spirally winding paper. The downstream hollow tubular element may be formed from multiple paper layers. The paper may have a basis weight of at least 50 g / m2, at least 60 g / m2, at least 70 g / m2, or at least 90 g / m2.

[0142] The downstream hollow tubular element may comprise a polymeric material. For example, the downstream hollow tubular element may comprise a polymeric film. The polymeric film may comprise a cellulose film. The downstream hollow tubular element may comprise low density polyethylene (LDPE) or polyhydroxyalkanoate (PHA) fibers. Preferably, the downstream hollow tubular element comprises cellulose acetate tow. For example, in a preferred embodiment, the downstream hollow tubular element comprises a hollow acetate tube.

[0143] Where the downstream hollow tubular element comprises cellulose acetate tow, the cellulose acetate tow may have a denier per filament of between 2 and 4 and a total denier of between 25 and 40.

[0144] In case the downstream section further comprises an additional downstream hollow tubular element, as described above, the additional downstream hollow tubular element may be formed of the same material as the downstream hollow tubular element or of a different material.

[0145] In certain preferred embodiments, the downstream section may include a ventilation zone at a location on the downstream hollow tubular element. In one example, this ventilation zone at a location on the downstream hollow tubular element may be provided instead of a ventilation zone at a location on the hollow tubular cooling element. In another example, a ventilation zone at a location on the downstream hollow tubular element may be provided in addition to the ventilation zone provided at a location on the hollow tubular cooling element.

[0146] The ventilation zone at a location along the downstream hollow tubular element may include a plurality of perforations through the peripheral wall of the downstream hollow tubular element. Preferably, the ventilation zone at a location along the downstream hollow tubular element includes at least one row of circumferential perforations. In some embodiments, the ventilation zone may include two rows of circumferential perforations. For example, the perforations may be formed on a production line during manufacture of the aerosol-generating article. Preferably, each row of circumferential perforations includes 8 to 30 perforations.

[0147] The aerosol generating article may include one or more hollow tubular elements. The one or more hollow tubular elements may form part of a downstream section of the aerosol generating article arranged downstream of the aerosol forming substrate portion. The one or more hollow tubular elements may include one or both of a hollow acetate tube (HAT) and a fine hollow acetate tube (FHAT). Such a hollow tube is a cylindrical component that may be made of cellulose acetate and has a centrally arranged axial hole. The size of the hollow tube (such as its outer diameter or the diameter of the hole) may vary and may be designed according to the requirements of the corresponding product.

[0148] The HAT may have a length between 6 mm and 10 mm, preferably between 7 mm and 9 mm, more preferably about 8 mm. The HAT may be arranged downstream of the aerosol-forming substrate portion, preferably downstream of the aerosol-forming substrate portion and directly adjacent to the aerosol-forming substrate portion. The HAT may be used as one or more of an airflow cooling element and an airflow accelerating element.

[0149] The FHAT may be arranged downstream of the HAT, preferably downstream of the HAT and directly adjacent to the HAT. The inner diameter of the FHAT may be larger than the inner diameter of the HAT. For example, the inner diameter of the FHAT may be about twice the size of the inner diameter of the HAT. The FHAT may be used as an airflow deceleration element.

[0150] The aerosol-generating article may include a mouth-end filter. The mouth-end filter may be arranged downstream of the aerosol-forming substrate portion. The mouth-end filter may be arranged at the proximal end of the aerosol-generating article. The mouth-end filter may be arranged downstream of the FHAT and directly adjacent to the FHAT.

[0151] The mouth end filter may include a filter material. The filter material may be a filamentary material, such as cellulose acetate. The denier of each filament may be 12. The denier of the filter material may be 12Y28.

[0152] The length of the mouth end filter along the longitudinal direction of the aerosol-generating article may be between 10 mm and 14 mm, preferably between 11 mm and 13 mm, more preferably about 12 mm.

[0153] The suction resistance of the mouth end filter may be between 1 mmH2O and 100 mmH2O, preferably between 2 mmH2O and 50 mmH2O, more preferably between 5 mmH2O and 40 mmH2O, more preferably between 10 mmH2O and 30 mmH2O, more preferably between 16 mmH2O and 20 mmH2O, more preferably between 17 mmH2O and 19 mmH2O, more preferably about 18 mmH2O. The suction resistance of the mouth end filter per mm length along the longitudinal direction of the aerosol generating article may be between 0.1 mmH2O and 20 mmH2O, preferably between 0.2 mmH2O and 10 mmH2O, between 0.5 mmH2O and 5 mmH2O, between 1 mmH2O and 2 mmH2O, more preferably between 1.3 mmH2O and 1.7 mmH2O, more preferably between 1.4 mmH2O and 1.6 mmH2O, more preferably about 1.5 mmH2O.

[0154] The aerosol-generating article according to the present disclosure may include an upstream section positioned upstream of the aerosol-forming substrate portion. The upstream section is preferably positioned immediately upstream of the aerosol-forming substrate portion. The upstream section preferably extends between the upstream end of the aerosol-generating article and the aerosol-forming substrate portion. The upstream section may include one or more upstream elements positioned upstream of the aerosol-forming substrate portion.

[0155] The aerosol-generating article of the present invention preferably comprises an upstream element positioned upstream of and adjacent to the aerosol-forming substrate portion. The upstream element advantageously prevents direct physical contact with the upstream end of the aerosol-forming substrate portion. Furthermore, the presence of the upstream element helps to prevent any loss of the substrate, which may be advantageous, for example, if the substrate contains particulate plant material.

[0156] Where the upstream segment of the aerosol-forming substrate portion comprises shredded tobacco (e.g. tobacco cut filler), the upstream segment or elements thereof may additionally help prevent loose tobacco particles from being lost from the upstream end of the article. This may be particularly important, for example, when the shredded tobacco has a relatively low density.

[0157] The upstream element may be a porous rod element. Preferably, the upstream element has a porosity of at least 50% in the longitudinal direction of the aerosol-generating article. More preferably, the upstream element has a porosity of between 50% and 90% in the longitudinal direction. The porosity of the upstream element in the longitudinal direction is defined by the ratio of the cross-sectional area of ​​the material forming the upstream element to the internal cross-sectional area of ​​the aerosol-generating article at the location of the upstream element.

[0158] The upstream element may be made of a porous material or may include a plurality of openings. For example, this may be achieved by laser perforation. Preferably, the plurality of openings are evenly distributed over the cross section of the upstream element.

[0159] The porosity or permeability of the upstream element may advantageously be designed to provide the aerosol-generating article with a particular overall resistance to draw (RTD) without substantially affecting the filtration provided by other parts of the article.

[0160] The upstream element may be formed from a material that is impermeable to air.In such embodiments, the aerosol-generating article may be configured such that air flows into the aerosol-forming substrate portion via suitable ventilation means provided in the packaging.

[0161] In certain preferred embodiments of the present invention, it may be desirable to minimize the RTD of the upstream element. For example, as described herein, this may be the case for an article that is intended to be inserted into the cavity of an aerosol generating device so that the aerosol-forming substrate is externally heated. For such articles, it is desirable to provide the article with as low an RTD as possible so that most of the RTD experience of the consumer is provided by the aerosol generating device rather than the article.

[0162] The RTD of upstream element can be less than 30 mm H2O, or less than 20 mm H2O, or less than 10 mm H2O, or less than 5 mm H2O, or less than 2 mm H2O. The RTD of upstream element can be at least 0.1 mm H2O, or at least 0.25 mm H2O, or at least 0.5 mm H2O. Preferably, the RTD of upstream element is less than 2 mm H2O / mm length, more preferably less than 1.5 mm H2O / mm length, more preferably less than 1 mm H2O / mm length, more preferably less than 0.5 mm H2O / mm length, more preferably less than 0.3 mm H2O / mm length, more preferably less than 0.2 mm H2O / mm length.

[0163] Preferably, the combined RTD of the upstream section, or upstream element thereof, and the aerosol-forming substrate portion is less than 15 mmH2O, more preferably less than 12 mmH2O, more preferably less than 10 mmH2O.

[0164] In certain preferred embodiments, the upstream element is formed by a solid cylindrical rod element having a filled cross section. Such rod elements may be referred to as "plain" elements. As described above, solid rod elements may be porous, but do not have a tubular form and therefore do not provide longitudinal flow channels. Solid rod elements preferably have a substantially uniform cross section.

[0165] In other preferred embodiments, the upstream element is formed by a hollow tubular segment defining a longitudinal cavity that provides an unrestricted flow passage. In such embodiments, as described above, the upstream element can provide protection for the aerosol-forming substrate while having minimal impact on the overall resistance to draw (RTD) and filtration characteristics of the article.

[0166] Preferably, the diameter of the longitudinal cavity of the hollow tubular segment forming the upstream element is at least 3 mm, more preferably at least 3.5 mm, more preferably at least 4 mm, and more preferably at least 4.5 mm. Preferably, the diameter of the longitudinal cavity is maximized in order to minimize the RTD of the upstream segment or its upstream element.

[0167] Preferably, the wall thickness of the hollow tubular segment is less than 2 mm, more preferably less than 1.5 mm, and more preferably less than 1 mm.

[0168] The upstream element of the upstream section may be made of any material suitable for use in an aerosol-generating article. The upstream element may, for example, be made of the same material as one of the other components of the aerosol-generating article, such as a downstream filter segment or a hollow tubular cooling element. Suitable materials for forming the upstream element include filter materials, ceramics, polymeric materials, cellulose acetate, paperboard, zeolites, or an aerosol-forming matrix. The upstream element may include a rod of cellulose acetate. The upstream element may include a hollow acetate tube or a paperboard tube.

[0169] Preferably, the upstream element is formed from a heat resistant material. For example, preferably, the upstream element is formed from a material that resists temperatures of up to 350 degrees Celsius. This ensures that the upstream element is not adversely affected by the heating means used to heat the aerosol-forming substrate.

[0170] Preferably, the upstream section or its upstream element has an outer diameter substantially equal to the outer diameter of the aerosol generating article. Preferably, the outer diameter of the upstream section or its upstream element is between 5 mm and 8 mm, more preferably between 5.25 mm and 7.5 mm, more preferably between 5.5 mm and 7 mm.

[0171] Preferably, the upstream section or upstream element has a length between 2 mm and 10 mm, more preferably between 3 mm and 8 mm, more preferably between 2 mm and 6 mm. In a particularly preferred embodiment, the upstream section or upstream element has a length of 5 mm.

[0172] The upstream section is preferably defined by a wrapper such as a stick wrapper. The wrapper defining the upstream section is preferably a rigid stick wrapper, for example, a stick wrapper having a basis weight of at least 80 g / m2, or at least 100 g / m2, or at least 110 g / m2. This provides structural rigidity to the upstream section.

[0173] The upstream section is preferably connected to the aerosol-forming substrate portion and optionally to at least a part of the downstream section by means of an outer wrapper.

[0174] The aerosol generating article may include an upstream section, which includes a front filter segment. The front filter segment may be arranged upstream of the aerosol forming substrate portion and directly adjacent to the aerosol forming substrate portion. The front filter segment may be arranged at the distal end of the aerosol generating article. The front filter segment may include filter material. The length of the front filter segment along the longitudinal direction of the aerosol generating article may be between 1 mm and 10 mm, preferably between 3 mm and 7 mm, more preferably between 4 mm and 6 mm, more preferably about 5 mm. The front filter segment may be in the form of a complete cylinder.

[0175] The ratio of substrate wrapper thickness to front filter segment diameter may be in the range of 0.007 to 0.03, preferably 0.015 to 0.027, more preferably 0.022 to 0.024.

[0176] The outer diameter of the front filter segment may differ from the outer diameter of the substrate wrapper defining the aerosol-forming substrate portion by less than 5%, preferably less than 3%, more preferably less than 1%, optionally wherein the outer diameter of the front filter segment is 7.1 mm.

[0177] The front filter segment may be defined by a front filter segment wrapper. The ratio of the thickness of the front filter segment wrapper to the thickness of the substrate wrapper may be 0.7 or less, more preferably 0.5 or less, more preferably 0.3 or less, more preferably 0.2 or less.

[0178] It is possible that no part of the front filter segment is defined by a substrate wrapper.

[0179] The suction resistance of the front filter segment may be between 1 mmH2O and 150 mmH2O, preferably between 1 mmH2O and 50 mmH2O, more preferably between 1 mmH2O and 20 mmH2O, more preferably between 1 mmH2O and 10 mmH2O. The suction resistance of the front filter segment may be about 10 mmH2O or less.

[0180] The front filter segment may help maintain the cleanliness of the aerosol generating device by capturing the slurry in the consumable.The front filter segment may prevent the aerosol-forming substrate or the heating element from falling out of the aerosol generating article.

[0181] Aerosol-generating articles according to the invention may have an overall length of at least 40 mm, or at least 50 mm, or at least 60 mm.

[0182] Aerosol-generating articles according to the invention may have an overall length of less than or equal to 90 mm, or less than or equal to 85 mm, or less than or equal to 80 mm.

[0183] In some embodiments, the overall length of the aerosol-generating article is preferably 50 mm to 90 mm, more preferably 60 mm to 90 mm, and even more preferably 70 mm to 90 mm. In other embodiments, the overall length of the aerosol-generating article is preferably 50 mm to 85 mm, more preferably 60 mm to 85 mm, and even more preferably 70 mm to 85 mm. In further embodiments, the overall length of the aerosol-generating article is preferably 50 mm to 80 mm, more preferably 60 mm to 80 mm, and even more preferably 70 mm to 80 mm. In an exemplary embodiment, the overall length of the aerosol-generating article is 75 mm.

[0184] In some embodiments, the overall length of the aerosol-generating article is preferably 40 mm to 70 mm, more preferably 45 mm to 70 mm. In other embodiments, the overall length of the aerosol-generating article is preferably 40 mm to 60 mm, more preferably about 45 mm to about 60 mm. In further embodiments, the overall length of the aerosol-generating article is preferably 40 mm to 50 mm, more preferably 45 mm to 50 mm. In an exemplary embodiment, the overall length of the aerosol-generating article is about 45 mm.

[0185] Preferably, the aerosol-generating article has an outer diameter of at least about 5 mm. More preferably, the aerosol-generating article has an outer diameter of at least 5.25 mm. Even more preferably, the aerosol-generating article has an outer diameter of at least 5.5 mm.

[0186] The aerosol-generating article preferably has an outer diameter less than or equal to 8 mm. More preferably, the aerosol-generating article has an outer diameter less than or equal to 7.5 mm. Even more preferably, the aerosol-generating article has an outer diameter less than or equal to 7 mm.

[0187] The aerosol-generating article may have an outer diameter of between 5 mm and 8 mm, or between 5 mm and 7.5 mm, or between 5 mm and 7 mm, or between 5.25 mm and 8 mm, or between 5.25 mm and 7.5 mm, or between 5.25 mm and 7 mm, or between 5.5 mm and 8 mm, or between 5.5 mm and 7.5 mm, or between 5.5 mm and 7 mm.

[0188] The outer diameter of the aerosol-generating article may be substantially constant over the entire length of the article. Alternatively, different parts of the aerosol-generating article may have different outer diameters.

[0189] Preferably, the overall RTD of the aerosol-generating article is at least 10 mmH2O. For example, the overall RTD of the aerosol-generating article may be at least 20 mmH2O, at least 30 mmH2O, at least 35 mmH2O or at least 40 mmH2O.

[0190] The overall RTD of the aerosol-generating article may be no more than 70 mm H2O. For example, the overall RTD of the aerosol-generating article may be no more than 65 mm H2O, no more than 60 mm H2O, or no more than 55 mm H2O, or no more than 50 mm.

[0191] The overall RTD of the aerosol generating article may be between 10 mmH2O and 70 mmH2O. For example, the overall RTD of the aerosol generating article may be between 20 mmH2O and 65 mmH2O, between 30 mmH2O and 60 mmH2O, between 35 mmH2O and 55 mmH2O, or between 40 mmH2O and 50 mmH2O.

[0192] In particularly preferred embodiments, one or more of the components of the aerosol-generating article is individually defined by its own wrapper.

[0193] In an embodiment, the aerosol-forming substrate portion and the mouthpiece element are wrapped separately. The upstream element, the aerosol-forming substrate portion and its defining substrate wrapper and the hollow tubular element are then combined together with an outer wrapper. Subsequently, they are combined with a downstream filter element having its own wrapper by means of tipping paper.

[0194] Preferably, at least one component of the aerosol-generating article is packaged in a hydrophobic wrapper.

[0195] The term "hydrophobic" refers to a surface that exhibits water repellent properties. A useful method for determining this is to measure the water contact angle. The "water contact angle" is the angle conventionally measured across a liquid when a liquid / vapor interface encounters a solid surface. It quantifies the wettability of a solid surface by a liquid via Young's equation. Hydrophobicity or water contact angle can be determined by utilizing the TAPPI T558 test method, and the results are presented as the interfacial contact angle and are reported in "degrees," and can range from near zero to near 180 degrees.

[0196] In a preferred embodiment, the hydrophobic wrapper is a wrapper comprising a paper layer having a water contact angle of about 30 degrees or greater, and preferably about 35 degrees or greater, or about 40 degrees or greater, or about 45 degrees or greater.

[0197] For example, the paper layer may include PVOH (polyvinyl alcohol) or silicon. PVOH may be applied to the paper layer as a surface coating, or the paper layer may include a surface treatment including PVOH or silicon.

[0198] The aerosol-generating article may comprise a tipping wrapper at least partially defining an aerosol-forming substrate portion and at least partially defining one or more portions of the aerosol-generating article adjacent to the aerosol-forming substrate portion. The one or more adjacent portions may comprise a front filter segment.

[0199] The tipping wrapper may be conventional cigarette paper. The tipping wrapper may have a grammage of less than 50 g / m2. The tipping wrapper may have a thickness of less than 70 microns or less than 50 microns. The tipping wrapper may have a thickness of about 65 microns and a grammage of about 45 g / m2.

[0200] The tipping wrapper may be thinner than the base wrapper. The ratio of the thickness of the tipping wrapper to the thickness of the base wrapper may be 0.7 or less, more preferably 0.5 or less, more preferably 0.3 or less, more preferably 0.2 or less.

[0201] The aerosol-generating article may include ventilation holes. The ventilation holes may promote nucleation of the aerosol. The ventilation holes may help cool the airflow. The ventilation holes may be provided in the FHAT. The FHAT may include 11 ventilation holes, each having a diameter of 0.11 mm.

[0202] The total resistance to suction of the aerosol generating article can be between 5 mm of water column and 200 mm of water column, preferably between 10 mm of water column and 150 mm of water column, more preferably between 20 mm of water column and 100 mm of water column, more preferably between 80 mm of water column and 80 mm of water column, more preferably between 40 mm of water column and 60 mm of water column, more preferably between 45 mm of water column and 55 mm of water column, more preferably about 48 mm of water column.

[0203] The aerosol-generating article may have a cylindrical shape.The aerosol-forming substrate portion may have a cylindrical shape.

[0204] The aerosol-generating article may comprise, in order from the proximal end to the distal end of the article, a mouth-end filter, one or more intermediate elements, an aerosol-forming substrate portion, and an optional front filter segment. The one or more intermediate elements may comprise one or more of a HAT, a FHAT, and a PLA rod. The total length of the article may be about 45 mm, and the length of the aerosol-forming substrate portion may be about 11 mm. The tipping wrapper may define the entire article or only a portion thereof.

[0205] The aerosol-forming substrate portion comprises a susceptor. The susceptor is at least partially defined by the aerosol-forming substrate. The susceptor may be completely surrounded by the aerosol-forming substrate. The susceptor may extend along substantially the entire length of the aerosol-forming substrate portion. This may provide an optimized heat distribution within the aerosol-forming substrate when the susceptor is heated. The susceptor may comprise a flat planar susceptor portion. The susceptor may be a flat planar susceptor strip. The susceptor may comprise a metal or an alloy. The susceptor may comprise aluminum.

[0206] As used herein, the term "flat planar" refers to a generally cuboid shape having a height that is significantly less than the width and length. For example, the width and length may each be at least twice the height of the cuboid. The height of the flat planar cuboid may also be referred to as the thickness of the susceptor or the flat planar susceptor portion.

[0207] The thickness of the susceptor element is typically 0.01 mm to 2 mm, such as 0.5 mm to 2 mm. In some embodiments, the susceptor element preferably has a thickness of 10 microns to 500 microns, more preferably 10 microns to 100 microns.

[0208] The susceptor may have a thickness of about 35 microns to about 85 microns. The susceptor may have a thickness of about 45 microns to about 75 microns. The susceptor may have a thickness of about 55 microns to about 65 microns.

[0209] The susceptor may be an elongate susceptor arranged substantially longitudinally within the aerosol-forming substrate portion.

[0210] The term "elongated" when used to describe a susceptor means that the susceptor has a length dimension that is greater than its width dimension or its thickness dimension, such as greater than twice its width dimension or its thickness dimension.

[0211] The susceptor may be arranged substantially longitudinally within the aerosol-forming substrate portion. This means that the length dimension of the elongate susceptor is arranged approximately parallel to the longitudinal direction of the aerosol-forming substrate, for example within plus or minus 10 degrees of parallel to the longitudinal direction of the aerosol-forming substrate. The elongate susceptor may be positioned at a radially central position within the aerosol-forming substrate portion and extend along the longitudinal axis of the aerosol-forming substrate portion.

[0212] The susceptors may be in the form of needles, strips, tapes or sheets.

[0213] The susceptor may have a length of about 5 mm to about 15 mm, such as about 6 mm to about 12 mm, more preferably about 8 mm to about 10 mm. The susceptor may have a length of about 11 mm.

[0214] The susceptor may have a width of at least about 1 mm, more preferably at least about 2 mm. Typically, the susceptor may have a width of up to 8 mm, preferably less than or equal to about 6 mm.

[0215] Preferably, the length of the elongated susceptor element is equal to or shorter than the length of the aerosol-forming substrate portion in which the elongated susceptor element is included. The length of the susceptor element may be 99% or less, 95% or less, 90% or less, 85% or less, 80% or less, 70% or less, 60% or less, 50% or less of the length of the aerosol-forming substrate portion in which the susceptor element is included. The length of the susceptor element may be between 70% and 99%, preferably between 75% and 95%, more preferably between 80% and 95%, more preferably between 85% and 95% of the length of the aerosol-forming substrate portion in which the susceptor element is included.

[0216] When the susceptor has a constant cross-section (eg, a circular cross-section), it may have a width or diameter of about 1 mm to about 5 mm.

[0217] When the susceptor has the form of a tape or sheet, the tape or sheet may have a rectangular cross-section, and its width is preferably about 2 mm to about 8 mm, more preferably about 3 mm to about 6 mm. The susceptor in the form of a tape or sheet may have a width of about 4 mm.

[0218] The elongated susceptor may have a thickness of about 57 microns to about 63 microns. Even more preferably, the elongated susceptor may have a thickness of about 58 microns to about 62 microns. Most preferably, the elongated susceptor has a thickness of about 60 microns.

[0219] The aerosol forms the suction resistance of the substrate part and can be between 0.1 mm H2O and 200 mm H2O, preferably between 1 mm H2O and 100 mm H2O, more preferably between 5 mm H2O and 40 mm H2O, more preferably between 10 mm H2O and 30 mm H2O, more preferably between 17 mm H2O and 29 mm H2O, preferably between 20 mm H2O and 26 mm H2O, more preferably about 23 mm H2O. The aerosol forms the suction resistance of the substrate part and can be 18 mm H2O or larger. The aerosol forms the suction resistance of the substrate part and can be 23 mm H2O or larger.

[0220] The aerosol-forming substrate portion has a low resistance to suction, for example less than 10 mm H2O, which may mean that there is only little interaction between the airflow and the aerosol-forming substrate, so that there is only little aerosolization. The aerosol-forming substrate portion has a high resistance to suction, for example more than 30 mm H2O, which may mean that the aerosol-forming substrate portion has a substantial effect on the overall resistance to suction of the aerosol-generating article. Due to manufacturing tolerances, the resistance to suction of the aerosol-forming substrate portion may vary to some extent from article to article. Reducing the effect of the aerosol-forming substrate portion on the overall resistance to suction of the aerosol-generating article may result in a more constant resistance to suction between different articles.

[0221] The resistance to draw of the aerosol-forming substrate portion per millimeter length of the aerosol-forming substrate portion may be between 0.1 mmH2O and 20 mmH2O, preferably between 0.2 mmH2O and 10 mmH2O, more preferably between 1 mmH2O and 5 mmH2O, more preferably between 1.7 mmH2O and 2.5 mmH2O, more preferably between 1.9 mmH2O and 2.3 mmH2O. The resistance to draw of the aerosol-forming substrate portion per millimeter length along the longitudinal direction of the aerosol-generating article may be about 2.1 mmH2O.

[0222] The total length of the aerosol-forming substrate portion in the direction along the longitudinal axis of the aerosol-generating article may be between 1 mm and 30 mm, preferably between 5 mm and 16 mm, more preferably between 9 mm and 13 mm, more preferably between 10 mm and 12 mm. The total length of the aerosol-forming substrate portion in the direction along the longitudinal axis of the aerosol-generating article may be 11 mm or less.

[0223] The total length of the aerosol-generating article may be between 10 mm and 150 mm, preferably between 20 mm and 1000 mm, more preferably between 30 mm and 80 mm, more preferably between 40 mm and 50 mm, more preferably between 43 mm and 47 mm, more preferably about 45 mm. The length of the aerosol-forming substrate along the longitudinal direction of the article may be between 22% and 26% of the total length of the aerosol-generating article, preferably about 24% of the total length of the aerosol-generating article.

[0224] The ratio between the total length of the aerosol-forming substrate portion and the overall length of the aerosol-generating article may be at least 0.20. Preferably, the ratio between the total length of the aerosol-forming substrate portion and the overall length of the aerosol-generating article is at least 0.25. More preferably, the ratio between the total length of the aerosol-forming substrate portion and the overall length of the aerosol-generating article is at least 0.30.

[0225] The ratio between the total length of the aerosol-forming substrate portion and the overall length of the aerosol-generating article is preferably less than or equal to 0.60. Preferably, the ratio between the total length of the aerosol-forming substrate portion and the overall length of the aerosol-generating article is less than or equal to 0.55. More preferably, the ratio between the total length of the aerosol-forming substrate portion and the overall length of the aerosol-generating article is less than or equal to 0.50.

[0226] In some embodiments, the ratio between the total length of the aerosol-forming substrate portion and the overall length of the aerosol-generating article is from 0.20 to 0.60, preferably from 0.20 to 0.55, more preferably from 0.20 to 0.50. In other embodiments, the ratio between the total length of the aerosol-forming substrate portion and the overall length of the aerosol-generating article is from 0.25 to 0.60, preferably from 0.25 to 0.55, more preferably from 0.25 to 0.50. In further embodiments, the ratio between the total length of the aerosol-forming substrate portion and the overall length of the aerosol-generating article is from 0.30 to 0.60, preferably from 0.30 to 0.55, more preferably from 0.30 to 0.50.

[0227] As used herein, the terms “external diameter” and “outer diameter” of an aerosol-generating article or component thereof may be calculated as the average of multiple measurements of the diameter of the aerosol-generating article or component thereof taken at different locations along the length of the aerosol-generating article or component thereof.

[0228] Preferably, the aerosol-generating article has an outer diameter of at least about 5 mm. More preferably, the aerosol-generating article has an outer diameter of at least 5.25 mm. Even more preferably, the aerosol-generating article has an outer diameter of at least 5.5 mm.

[0229] The aerosol-generating article preferably has an outer diameter less than or equal to 8 mm. More preferably, the aerosol-generating article has an outer diameter less than or equal to 7.5 mm. Even more preferably, the aerosol-generating article has an outer diameter less than or equal to 7 mm.

[0230] Preferably, the aerosol-generating article has a substantially circular cross-section.Preferably, the aerosol-generating article has a substantially uniform cross-section along the entire length of the aerosol-generating article.

[0231] The total density of the aerosol-forming substrate portion may be greater than 0.71 mg / mm3. The total density of the aerosol-forming substrate portion may be 0.715 mg / mm3 or greater. The total density of the aerosol-forming substrate portion may be 0.720 mg / mm3 or greater. The total density of the aerosol-forming substrate portion may be about 0.725 mg / mm3.

[0232] For example, the substrate wrapper can define a cylindrical volume with a diameter of 6.77 millimeters and a length of 11 millimeters, i.e., a volume of 396 cubic millimeters. The volume can be filled with an aerosol-forming substrate and a susceptor. The total mass of the aerosol-forming substrate in the aerosol-forming substrate portion can be 266 milligrams, and the total mass of the susceptor material in the aerosol-forming substrate portion can be 21.2 milligrams. Then, the total density of the aerosol-forming substrate portion corresponds to 287.2 milligrams divided by 396 cubic millimeters, i.e., 0.725 milligrams / cubic millimeter.

[0233] Taking into account the mass and volume of the substrate wrapper and one or more optional further wrappers defining the substrate wrapper, the overall density of the aerosol-generating article at a longitudinal position of the aerosol-forming substrate portion may be about 0.66 mg / mm3.

[0234] The ratio of the total density of the aerosol-forming substrate portion divided by the total density of the aerosol-generating article at a longitudinal position of the aerosol-forming substrate portion may be greater than 1.0, preferably greater than 1.05, more preferably 1.09 or more.

[0235] At least 70% by volume, preferably at least 75% by volume, more preferably at least about 79% by volume of the internal volume of the aerosol-forming substrate portion may be filled with the aerosol-forming substrate and one or more susceptor elements.

[0236] Less than 30% by volume, preferably less than 25% by volume, more preferably about 21% by volume or less of the internal volume of the aerosol-forming substrate portion may be empty.

[0237] The total mass of the aerosol-forming substrate in the aerosol-forming substrate portion may be less than 300 mg, preferably less than 290 mg. The total mass of the aerosol-forming substrate in the aerosol-forming substrate portion may be about 266 mg. The total mass of the aerosol-forming substrate in the aerosol-forming substrate portion may be between 10 mg and 3000 mg, preferably between 50 mg and 1000 mg, more preferably between 100 mg and 500 mg, more preferably between 200 mg and 400 mg, more preferably between 250 mg and 350 mg, more preferably between 260 mg and 270 mg, more preferably between 263 mg and 269 mg.

[0238] The aerosol-forming substrate portion comprises an aerosol-forming substrate and a susceptor. The total mass of the susceptor material in the aerosol-forming substrate portion may be between 1 mg and 100 mg, preferably between 5 mg and 50 mg, more preferably between 10 mg and 40 mg, more preferably between 15 mg and 25 mg, more preferably between 20 mg and 23 mg, more preferably between 20.5 mg and 21.7 mg.

[0239] The aerosol-forming substrate portion may comprise an aerosol-forming substrate and a susceptor, and the total mass of the susceptor material in the aerosol-forming substrate portion may be between 20.5 mg and 21.7 mg, and the total mass of the aerosol-forming substrate in the aerosol-forming substrate portion may be between 263 mg and 269 mg.

[0240] The density of the aerosol-forming substrate may be greater than 800 kg / m3, preferably greater than 825 kg / m3, more preferably may be about 842 kg / m3.

[0241] The aerosol-forming substrate may be provided in the form of a sheet. The sheet of aerosol-forming substrate may be gathered when inserted into the aerosol-forming substrate portion. The density of the sheet of aerosol-forming substrate may be determined by dividing the grammage of the sheet by the thickness of the sheet before gathering the sheet.

[0242] The aerosol-forming substrate may be provided in the form of a gathered sheet of homogenised tobacco material.

[0243] The sheet of homogenised tobacco material may have a grammage of less than 210 g / m2, preferably less than 200 g / m2, more preferably about 192 g / m2.

[0244] The sheet of homogenised tobacco material may have a thickness of greater than 215 microns, preferably greater than 220 microns, more preferably about 228 microns.

[0245] The sheet material of homogenized tobacco material can be a cast sheet material.Before the cast process, the homogenized tobacco material can include tobacco particles with a mean particle size (D95) greater than 50 microns, preferably greater than 50 microns and less than 100 microns, more preferably between 60 microns and 80 microns, more preferably between 65 microns and 75 microns, more preferably about 70 microns.This tobacco particle size (D95) can produce the rough surface of the sheet material.This may cause the surface area of ​​the sheet material to increase.The increased surface can improve aerosolization.When the total mass of the aerosol-forming substrate in the aerosol-forming substrate part decreases, this may be particularly advantageous.As used herein, the term "mean particle size (D95)" is used to represent the median value based on volume of particle size distribution, and is the value of 95% of the particle diameter in the cumulative distribution.The particle size of the particle can be analyzed by laser diffraction method.

[0246] The aerosol-forming substrate may comprise tobacco material, from about 1% to about 5% binder and from about 10% to about 30% glycerol by dry weight.

[0247] The aerosol-forming substrate portion may define a substantially cylindrical shape. The cylindrical shape of the aerosol-forming substrate portion may have a diameter in the range of about 3 mm to about 10 mm, preferably about 6 mm to about 8 mm, more preferably about 6.5 mm to about 7.5 mm, more preferably about 6.6 mm to about 7.0 mm, more preferably about 6.7 mm to about 6.9 mm, more preferably about 6.75 mm to about 6.85 mm. The cylindrical shape of the aerosol-forming substrate portion may have a diameter in the range of about 6.8 mm to about 7.1 mm, or about 6.8 mm to about 7.0 mm.

[0248] The present invention also relates to a package comprising a plurality of aerosol-generating articles, wherein each aerosol-generating article in the package is an aerosol-generating article as described herein.

[0249] The present invention also relates to an aerosol generating system comprising an aerosol generating article and an aerosol generating device as described herein. The aerosol generating device may include a heating chamber configured to at least partially insert the aerosol generating article into the heating chamber. The aerosol generating device may include an internal heating element arranged to be inserted into the aerosol generating article when the aerosol generating article is at least partially inserted into the heating chamber. The aerosol generating device may include an inductor coil. The inductor coil may at least partially define the heating chamber. The inductor coil may be arranged to coaxially define the heating chamber. The inductor coil may be arranged to inductively heat a susceptor element. The susceptor element may be part of the internal heating element of the aerosol generating device. The susceptor element may be part of the aerosol generating article. The inductor coil may be arranged to inductively heat a susceptor of the aerosol generating article when the aerosol generating article is at least partially inserted into the heating chamber.

[0250] As used herein, the term "aerosol-forming substrate" refers to a substrate that is capable of releasing volatile compounds that can form an aerosol. Such volatile compounds can be released by heating the aerosol-forming substrate. The aerosol-forming substrate can be in solid form or can be in liquid form. The aerosol-forming substrate can be solid or liquid, or can include both solid and liquid components. The aerosol-forming substrate can be part of an aerosol-generating article. The terms "aerosol" and "vapor" are used synonymously.

[0251] The aerosol-forming substrate may comprise one or more of: tobacco, nicotine, an aerosol-forming film, a gel composition and flavourings.The aerosol-forming substrate may comprise homogenised tobacco material, such as cast leaf, aerosol-forming film and a gel composition.

[0252] The aerosol-forming matrix may include one or more aerosol formers. The aerosol former may be any suitable known compound or mixture of compounds that contributes to the formation of a dense and stable aerosol in use. The aerosol former may facilitate the aerosol to be substantially resistant to thermal degradation at temperatures typically applied during the use of the aerosol-generating article. Suitable aerosol formers are, for example: polyols, such as triethylene glycol, 1,3-butylene glycol, propylene glycol and glycerol; esters of polyols, such as glycerol mono-, di- or triacetate; aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate; and combinations thereof. Preferably, the one or more aerosol formers include one or both of glycerol and propylene glycol. The one or more aerosol formers may consist of one or both of glycerol and propylene glycol. Preferably, the aerosol-forming matrix includes glycerol. The terms "glycerol" and "glycerol" are used synonymously herein.

[0253] The aerosol-forming substrate may comprise less than or equal to 80% by weight of aerosol-forming agent based on the dry weight of the aerosol-forming substrate. The aerosol-forming substrate may comprise less than or equal to 60% by weight of aerosol-forming agent based on the dry weight of the aerosol-forming substrate. The aerosol-forming substrate may comprise less than or equal to 40% by weight of aerosol-forming agent based on the dry weight of the aerosol-forming substrate. The aerosol-forming substrate may comprise less than or equal to 20% by weight, or less than or equal to 15% by weight of aerosol-forming agent based on the dry weight of the aerosol-forming substrate.

[0254] The aerosol-forming substrate may comprise between 5 wt % and 80 wt %, or between 5 wt % and 60 wt %, or between 5 wt % and 40 wt %, or between 5 wt % and 20 wt %, or between 5 wt % and 15 wt %, or between 7 wt % and 80 wt %, or between 7 wt % and 60 wt %, or between 7 wt % and 40 wt %, or between 7 wt % and 20 wt %, or between 7 wt % and 15 wt %, or between 10 wt % and 80 wt %, or between 10 wt % and 60 wt %, or between 10 wt % and 40 wt %, or between 10 wt % and 20 wt %, or between 10 wt % and 15 wt % of aerosol-forming agent, based on the dry weight of the aerosol-forming substrate.

[0255] Aerosol formation substrate can comprise tobacco material.Aerosol formation substrate can comprise shredded tobacco material.For example, as described in more detail below, shredded tobacco material can be in the form of shredded filler.Alternately, shredded tobacco material can be in the form of shredded material of homogenized tobacco material.Suitable homogenized tobacco material for the present invention is described below.

[0256] In the context of this specification, the term "cut filler" is used to describe a blend of chopped plant material, such as tobacco plant material, including in particular one or more of leaves, processed stems and ribs, and homogenised plant material.

[0257] Cut filler may also include other post-cut filler tobaccos or addenda.

[0258] Preferably, the shredded filler comprises at least 25% plant leaves, more preferably at least 50% plant leaves, still more preferably at least 75% plant leaves, and most preferably at least 90% plant leaves. Preferably, the plant material is one of tobacco, mint, tea and cloves. Most preferably, the plant material is tobacco. However, the present invention is equally applicable to other plant materials having the ability to release a substance upon application of heat and subsequently form an aerosol.

[0259] Preferably, the cut filler comprises tobacco plant material including thin layers of one or more of flue-cured tobacco, sun-cured tobacco, oriental tobacco and filler tobacco.With reference to the present invention, the term "tobacco" describes any plant member of the genus Nicotiana.

[0260] Cut filler suitable for use with the present invention may be generally similar to cut filler used in conventional smoking articles. The cut width of the cut filler may preferably be between 0.3 mm and 2.0 mm, or between 0.5 mm and 1.2 mm, or between 0.6 mm and 0.9 mm.

[0261] Preferably, the strand has a length of between about 10 millimetres and about 40 millimetres prior to being collated to form the aerosol-forming substrate portion.

[0262] In a preferred embodiment, the weight of the cut filler is between 80 mg and 400 mg, preferably between 120 mg and 250 mg, more preferably between 150 mg and 200 mg. This amount of cut filler generally allows sufficient material for forming an aerosol.

[0263] Preferably, the shredded filler is soaked with an aerosol former. Soaking the shredded filler can be done by spraying or by other suitable application methods. The aerosol former can be applied to the blend during the preparation of the shredded filler. For example, the aerosol former can be applied to the blend in a direct conditioning casing cylinder (DCCC). The aerosol former can be applied to the shredded filler using a conventional machine. Suitable aerosol formers can be the aerosol formers described herein. Preferably, the aerosol former in the shredded filler includes one or both of glycerol and propylene glycol. The aerosol former can consist of glycerol or propylene glycol or a combination of glycerol and propylene glycol.

[0264] The aerosol-forming substrate may comprise homogenised plant material, for example homogenised tobacco material.

[0265] As used herein, the term "homogenized plant material" includes any plant material formed by the agglomeration of plant particles. For example, a sheet or web of homogenized plant material for forming an aerosol substrate of the present invention can be formed by agglomerating plant material particles obtained by pulverizing, grinding or crushing plant material. Homogenized plant material can be produced by casting, extrusion, papermaking technology or any other suitable process known in the art. Homogenized plant material can be provided in any suitable form.

[0266] In some embodiments, the homogenised plant material may be in the form of one or more sheets.As used herein with reference to the present invention, the term "sheet" describes a laminar element having a width and length substantially greater than its thickness.

[0267] The homogenized plant material may be in the form of a plurality of pellets or granules.

[0268] Homogenized plant material can be in the form of multiple strands, bands or fragments. As used herein, the term "strand" describes an elongated element material whose length is significantly greater than its width and thickness. The term "strand" should be considered to include bands, fragments and any other homogenized plant material with similar forms. The strand of homogenized plant material can be formed by a sheet of homogenized plant material, such as by cutting or chopping, or by other methods, such as by extrusion methods.

[0269] As mentioned above, when the homogenised plant material is in the form of one or more sheets, the sheets may be produced by a casting process. Alternatively, the sheets of homogenised plant material may be produced by a papermaking process.

[0270] One or more sheets as described herein may each individually have a thickness between 100 and 600 microns, preferably between 150 and 300 microns, and most preferably between 200 and 250 microns. Individual thickness refers to the thickness of an individual sheet, while combined thickness refers to the total thickness of all sheets constituting the aerosol-forming substrate.

[0271] One or more sheets as described herein may each individually have a grammage between 100 g / m2 and 600 g / m2.

[0272] One or more sheets as described herein may each individually have a density of 0.3 g / cm3 to 1.3 g / cm3, and preferably 0.7 g / cm3 to 1.0 g / cm3.

[0273] One or more sheets as described herein may be one or more of curled, folded, gathered, and pleated.

[0274] One or more sheets of homogenized plant material can be cut into stocks as described above. In such embodiments, the aerosol formation matrix comprises a plurality of homogenized plant material stocks. Stock can be used to form a rod. Usually, the width of these stocks is about 5 millimeters, or about 4 millimeters, or about 3 millimeters, or about 2 millimeters or less. The length of stock can be greater than about 5 millimeters, between about 5 millimeters and about 15 millimeters, about 8 millimeters to about 12 millimeters, or is about 12 millimeters. Preferably, stock has substantially the same length as each other.

[0275] The homogenized plant material may include between 2.5 wt% and 95 wt% plant particles, or between 5 wt% and 90 wt% plant particles, or between 10 wt% and 80 wt% plant particles, or between 15 wt% and 70 wt% plant particles, or between 20 wt% and 60 wt% plant particles, or between 30 wt% and 50 wt% plant particles on a dry weight basis.

[0276] In certain embodiments of the present invention, the homogenized plant material is a homogenized tobacco material comprising tobacco particles. The sheet of homogenized tobacco material for such embodiments of the present invention can have a tobacco content of at least about 40% by weight on a dry basis, more preferably at least about 50% by weight on a dry basis, more preferably at least about 70% by weight on a dry basis, and most preferably at least about 90% by weight on a dry basis.

[0277] With reference to the present invention, term " tobacco particles " describes the particle of any plant member of Nicotiana.Term " tobacco particles " comprises ground or pulverized tobacco leaf blade, ground or pulverized tobacco leaf stem, tobacco dust, tobacco fines and other particle tobacco byproducts formed in the processing, operation and transportation process of tobacco.In a preferred embodiment, tobacco particles are all derived from tobacco leaf blade basically.By contrast, isolated nicotine and nicotine salt are compounds derived from tobacco, but are not considered to tobacco particles for purposes of the present invention, and are not included in the percentage of granular plant material.

[0278] In a preferred embodiment, the aerosol-forming substrate comprises a homogenized tobacco material strand, wherein the weight of the homogenized tobacco material strand is between 50 mg and 2000 mg, preferably between 80 mg and 400 mg, more preferably between 120 mg and 250 mg, more preferably between 150 mg and 200 mg. This amount of homogenized tobacco material strand generally allows enough material to form an aerosol.

[0279] The aerosol-forming substrate may be in the form of an aerosol-forming film comprising a cellulose-based film-forming agent, nicotine and an aerosol-forming agent. The aerosol-forming film may further comprise a cellulose-based reinforcing agent. The aerosol-forming film may further comprise water, preferably 30 wt% or less of water.

[0280] As used herein, the term "film" is used to describe a solid laminar element whose thickness is less than its width or length. The film can be self-supporting. In other words, the film can have cohesive and mechanical properties so that the film can be separated from the supporting surface even if it is obtained by casting a film preparation on the supporting surface. Alternatively, the film can be arranged on a support or sandwiched between other materials. This can enhance the mechanical stability of the film.

[0281] The aerosol-forming film may comprise one or more aerosol-forming agents as described herein, preferably, the aerosol-forming agent comprises glycerol, or is glycerol. The aerosol-forming film may have an aerosol-forming agent content of at least 5% by weight on a dry weight basis. The aerosol-forming film may have an aerosol-forming agent content of at least 15% by weight on a dry weight basis. The aerosol-forming film may have an aerosol-forming agent content of at least 20% by weight on a dry weight basis. The aerosol-forming film may have an aerosol-forming agent content of at least 30% by weight on a dry weight basis. Preferably, the aerosol-forming film has an aerosol-forming agent content of at least 40% by weight on a dry weight basis. More preferably, the aerosol-forming film has an aerosol-forming agent content of at least 45% by weight on a dry weight basis. More preferably, the aerosol-forming film has an aerosol-forming agent content of at least 50% by weight on a dry weight basis.

[0282] Preferably, the aerosol-forming film has an aerosol-forming agent content of no more than 80 wt-% on a dry weight basis. More preferably, the aerosol-forming film has an aerosol-forming agent content of no more than 75 wt-% on a dry weight basis. More preferably, the aerosol-forming film has an aerosol-forming agent content of no more than 70 wt-% on a dry weight basis.

[0283] In the context of the present invention, the term "cellulose-based film former" is used to describe a cellulosic polymer that is capable of forming a continuous film, either alone or in the presence of an auxiliary thickener.

[0284] Preferably, the cellulose-based film former is selected from hydroxypropyl methylcellulose (HPMC), methylcellulose (MC), ethylcellulose (EC), hydroxyethyl methylcellulose (HEMC), hydroxyethyl cellulose (HEC), hydroxypropyl cellulose (HPC) and combinations thereof.

[0285] More preferably, the cellulose-based film former is selected from hydroxypropylmethylcellulose (HPMC), methylcellulose (MC), ethylcellulose (EC) and combinations thereof.

[0286] In a particularly preferred embodiment, the cellulose-based film former is HPMC.

[0287] The aerosol-generating film may have a cellulose-based film-forming agent content of between 10 wt% and 40 wt%, alternatively between 15 wt% and 35 wt%, alternatively between 20 wt% and 30 wt%, based on dry weight.

[0288] Preferably, the aerosol-generating film further comprises a cellulose-based reinforcing agent.Preferably, the cellulose-based reinforcing agent is selected from the group consisting of cellulose fibers, microcrystalline cellulose (MCC), cellulose powder and combinations thereof.

[0289] The aerosol-generating film may have a cellulose-based strengthening agent content of between 0.5 wt% and 40 wt% on a dry basis, or between 5 wt% and 30 wt% on a dry basis, or between 10 wt% and 25 wt% on a dry basis.

[0290] The aerosol-forming film may further comprise carboxymethylcellulose, preferably sodium carboxymethylcellulose.

[0291] The aerosol-generating film may have a carboxymethylcellulose content of between 1 wt% and 15 wt%, alternatively between 2 wt% and 12 wt%, alternatively between 4 wt% and 10 wt%, based on dry weight.

[0292] The aerosol-generating film preferably comprises nicotine.

[0293] As used herein with respect to the present invention, the term "nicotine" is used to describe nicotine, nicotine base or nicotine salt. In embodiments where the aerosol-generating film comprises nicotine base or nicotine salt, the amount of nicotine recited herein is the amount of free base nicotine or the amount of protonated nicotine, respectively.

[0294] The aerosol-generating film may comprise natural nicotine or synthetic nicotine.

[0295] The aerosol-generating film may comprise one or more monobasic nicotine salts.

[0296] As used herein with respect to the present invention, the term "monobasic nicotine salt" is used to describe the nicotine salt of the monobasic acid.

[0297] Preferably, the aerosol-generating film comprises at least 0.5% by weight of nicotine on a dry weight basis. More preferably, the aerosol-generating film comprises at least 1% by weight of nicotine on a dry weight basis. Even more preferably, the aerosol-generating film comprises at least 2% by weight of nicotine on a dry weight basis. Additionally, or as an alternative, the aerosol-generating film preferably comprises less than 10% by weight of nicotine on a dry weight basis. More preferably, the aerosol-generating film comprises less than 8% by weight of nicotine on a dry weight basis. More preferably, the aerosol-generating film comprises less than 6% by weight of nicotine on a dry weight basis.

[0298] For example, the aerosol-generating film may comprise between 0.5 wt% and 10 wt% nicotine, or between 1 wt% and 8 wt% nicotine, or between 2 wt% and 6 wt% nicotine on a dry weight basis.

[0299] The aerosol-generating film may be a substantially tobacco-free aerosol-generating film.

[0300] In a preferred embodiment, the aerosol-forming film comprises an acid. More preferably, the aerosol-forming film comprises one or more organic acids. Even more preferably, the aerosol-forming film comprises one or more carboxylic acids. In a particularly preferred embodiment, the acid is lactic acid, benzoic acid, fumaric acid or levulinic acid.

[0301] Preferably, the aerosol-generating film comprises between 0.25 and 3.5 wt% acid, or between 0.5 and 3 wt% acid, or between 1 and 2.5 wt% acid on a dry weight basis.

[0302] The aerosol-generating film may have a thickness of about 0.1 mm to about 1 mm, more preferably about 0.1 mm to about 0.75 mm, even more preferably about 0.1 mm to about 0.5 mm. In a particularly preferred embodiment, the thickness of the film-forming composition layer formed is about 50 μm to 400 μm, more preferably about 100 μm to 200 μm.

[0303] The aerosol-generating film may optionally be provided on a suitable carrier element.

[0304] The aerosol-forming substrate may comprise a gel composition comprising nicotine, at least one gelling agent and an aerosol former. The gel composition is preferably substantially free of tobacco.

[0305] Preferred weight ranges for nicotine in the gel composition are the same as those defined above for the aerosol-forming film.

[0306] The gel composition preferably comprises at least 50 wt% aerosol former, more preferably at least 60 wt% aerosol former, more preferably at least 70 wt% aerosol former, based on dry weight. The gel composition may comprise up to 80 wt% aerosol former. The aerosol former in the gel composition is preferably glycerol.

[0307] The gel composition preferably includes at least one gelling agent. Preferably, the gel composition includes a total amount of gelling agent in the range of about 0.4 wt % to about 10 wt %, or about 0.5 wt % to about 8 wt %, or about 1 wt % to about 6 wt %, or about 2 wt % to about 4 wt %, or about 2 wt % to about 3 wt %.

[0308] The term "gelling agent" refers to a compound that, when added to a mixture of 50 wt % water / 50 wt % glycerol in an amount of about 0.3 wt %, homogeneously forms a solid medium or support matrix that results in a gel. Gelling agents include, but are not limited to, hydrogen bond cross-linking gelling agents and ionic cross-linking gelling agents.

[0309] The term "hydrogen-bonding cross-linking gelling agent" refers to a gelling agent that forms non-covalent cross-links or physical cross-links via hydrogen bonds.

[0310] The hydrogen-bond cross-linking gelling agent may include one or more of galactomannan, gelatin, agarose or konjac gum or agar. The hydrogen-bond cross-linking gelling agent may preferably include agar.

[0311] The term "ionic cross-linking gelling agent" refers to a gelling agent that forms non-covalent cross-links or physical cross-links through ionic bonds.

[0312] The ionically cross-linked gelling agent may include low acyl gellan gum, pectin, kappa carrageenan, iota carrageenan or alginate. The ionically cross-linked gelling agent may preferably include low acyl gellan gum.

[0313] The gelling agent may include one or more biopolymers. The biopolymer may be formed from a polysaccharide.

[0314] Biopolymers include, for example, gellan gum (natural, low acyl gellan gum, high acyl gellan gum, preferably low acyl gellan gum), xanthan gum, alginates (alginic acid), agar, guar gum, etc. The composition may preferably include xanthan gum. The composition may include two biopolymers. The composition may include three biopolymers. The composition may include substantially equal weights of two biopolymers. The composition may include substantially equal weights of three biopolymers.

[0315] The gel composition may also include a viscosity increasing agent. The viscosity increasing agent in combination with the hydrogen bonding cross-linking gelling agent and the ionic cross-linking gelling agent appears to unexpectedly support the solid medium and maintain the gel composition even when the gel composition includes high levels of glycerol.

[0316] The term "viscosity increasing agent" refers to a compound that, when homogeneously added in an amount of 0.3 wt% to a mixture of 50 wt% water / 50 wt% glycerol at 25°C, increases viscosity without causing gel formation, the mixture remaining or remaining fluid.

[0317] The gel composition preferably includes a viscosity increasing agent in the range of about 0.2 wt % to about 5 wt %, or about 0.5 wt % to about 3 wt %, or about 0.5 wt % to about 2 wt %, or about 1 wt % to about 2 wt %.

[0318] The thickener may include one or more of xanthan gum, carboxymethyl cellulose, microcrystalline cellulose, methyl cellulose, gum arabic, guar gum, lambda-carrageenan or starch. The thickener may preferably include xanthan gum.

[0319] The gel composition may also include divalent cations. Preferably, the divalent cations include calcium ions, such as calcium lactate in solution. For example, divalent cations such as calcium ions can help form a gel of a composition including a gelling agent such as an ionically cross-linked gelling agent. Ionic effects can help gel formation. The divalent cations can be present in the gel composition in a range of about 0.1% to about 1% by weight, or about 0.5% by weight.

[0320] The gel composition may also include an acid. The acid may include a carboxylic acid. The carboxylic acid may include a keto group. Preferably, the carboxylic acid may include a keto group having less than about 10 carbon atoms, or less than about 6 carbon atoms, or less than about 4 carbon atoms, such as levulinic acid or lactic acid. Preferably, the carboxylic acid has three carbon atoms (such as lactic acid).

[0321] The gel composition preferably includes some water. When the gel composition includes some water, the gel composition is more stable.

[0322] Preferably, the gel composition comprises water in an amount of from about 8 wt % to about 32 wt %, or from about 15 wt % to about 25 wt %, or from about 18 wt % to about 22 wt %, or about 20 wt %.

[0323] Preferably, where a gel composition is used, the aerosol-forming substrate comprises a porous medium loaded with the gel composition. An advantage of a porous medium loaded with the gel composition is that the gel composition is retained within the porous medium, and this may aid in the manufacture, storage or transport of the gel composition. It may help maintain the desired shape of the gel composition, particularly during manufacture, transport or use.

[0324] The term "porous" is used herein to refer to a material that provides a plurality of pores or openings that allow air to pass through the material.

[0325] The porous medium can be any suitable porous material capable of containing or retaining the gel composition. Ideally, the porous medium allows the gel composition to move therein. In particular embodiments, the porous medium comprises a natural material, a synthetic or semi-synthetic material, or a combination thereof. In particular embodiments, the porous medium comprises a sheet material, a foam or a fiber, such as a loose fiber; or a combination thereof. In particular embodiments, the porous medium comprises a woven, non-woven or extruded material, or a combination thereof. Preferably, the porous medium comprises cotton, paper, viscose, PLA or cellulose acetate, or a combination thereof. Preferably, the porous medium comprises a sheet material, such as cotton or cellulose acetate. In a particularly preferred embodiment, the porous medium comprises a sheet made of cotton fibers.

[0326] The porous media may be curled or shredded.The porous media may be in the form of sheets, wires or tubular elements.

[0327] The aerosol-forming substrate may comprise nicotine. The nicotine-containing aerosol-forming substrate may be a nicotine salt substrate.

[0328] Preferably, the aerosol-forming substrate comprises a plant material and an aerosol-forming agent. Preferably, the plant material is an alkaloid-containing plant material, more preferably a nicotine-containing plant material, and more preferably a tobacco-containing material.

[0329] Preferably, the aerosol-forming substrate comprises at least 70% by weight of plant material, more preferably at least 90% by weight of plant material, by dry weight. Preferably, the aerosol-forming substrate comprises less than 95% by weight of plant material, such as 90% to 95% by weight of plant material, by dry weight.

[0330] Preferably, the aerosol-forming substrate comprises at least 5 wt% aerosol-forming agent on a dry weight basis, more preferably at least 10 wt% aerosol-forming agent. Preferably, the aerosol-forming substrate comprises less than 30 wt% aerosol-forming agent on a dry weight basis, more preferably from 5 wt% to 30 wt% aerosol-forming agent on a dry weight basis.

[0331] In some particularly preferred embodiments, the aerosol-forming matrix comprises a plant material and an aerosol-forming agent, wherein the matrix has an aerosol-forming agent content between 5% by weight and 30% by weight on a dry weight basis. The plant material is preferably a plant material comprising an alkaloid, more preferably a plant material comprising nicotine, and more preferably a tobacco-containing material. Alkaloids are a class of naturally occurring nitrogen-containing organic compounds. Alkaloids are mainly found in plants, but are also found in bacteria, fungi and animals. Examples of alkaloids include, but are not limited to, caffeine, nicotine, theobromine, atropine and tubocurarine. A preferred alkaloid is nicotine, which is found in tobacco.

[0332] Aerosol forms a matrix that can comprise nicotine.Aerosol forms a matrix that can comprise tobacco, for example can comprise a tobacco-containing material that contains volatile tobacco aroma compounds, and this volatile tobacco aroma compounds releases from aerosol formation matrix when heated.In a preferred embodiment, aerosol forms a matrix that can comprise homogenized tobacco material, for example cast leaf tobacco.Aerosol forms a matrix that can comprise both solid components and liquid components.Aerosol forms a matrix that can comprise a tobacco-containing material, and this tobacco-containing material contains the volatile tobacco aroma compounds that releases from matrix when heated.Aerosol forms a matrix that can comprise non-tobacco material.Aerosol forms a matrix that can also comprise an aerosol-forming agent.The example of a suitable aerosol-forming agent is glycerol and propylene glycol.

[0333] As used herein, the term "tobacco material" is used to describe any material comprising tobacco, including but not limited to tobacco leaves, tobacco ribs, tobacco stems, tobacco stalks, tobacco dust, expanded tobacco, reconstituted tobacco material, and homogenized tobacco material.

[0334] As used herein, the term "homogenized tobacco" refers to a material formed by agglomerating particulate tobacco. Homogenized tobacco may include reconstituted tobacco or cast leaf tobacco, or a mixture of the two. The term "reconstituted tobacco" refers to a paper-like material that can be made from tobacco byproducts such as tobacco fines, tobacco dust, tobacco stems, or a mixture of the foregoing. Reconstituted tobacco can be prepared by extracting soluble chemicals from tobacco byproducts, processing remaining tobacco fibers into thin sheets, and then reapplying the extracted material to the thin sheets in a concentrated form.

[0335] The term "cast leaf" is used herein to refer to a sheet product manufactured by a casting process, which is based on casting a slurry comprising plant particles (e.g., clove particles or tobacco particles and clove particles in a mixture) and a binder (e.g., guar gum) onto a support surface (e.g., a belt conveyor), drying the slurry and removing the dried sheet from the support surface. Examples of casting or cast leaf processes are described in, for example, US-A-5,724,998 for the manufacture of cast leaf tobacco. In the cast leaf process, a granular plant material is mixed with a liquid component (usually water) to form a slurry. Other added components in the slurry may include fibers, a binder, and an aerosol forming agent. The granular plant material may coalesce in the presence of a binder. The slurry is cast onto a support surface and dried to form a homogenized plant material sheet.

[0336] As used herein, the term "flavor" refers to a component with organoleptic properties that provides a sensory experience to the user, such as to enhance the fragrance of an aerosol. Flavors can be used to deliver a taste (flavor), smell (smell), or both a taste and smell to the user, such as when an aerosol is inhaled.

[0337] As used herein, the term "aerosol-generating article" refers to an article comprising an aerosol-forming substrate capable of releasing volatile compounds that can form an aerosol. The aerosol-generating article may be disposable. An aerosol-generating article comprising an aerosol-forming substrate (including tobacco) may be referred to herein as a tobacco rod.

[0338] As used herein, the term "aerosol generating device" refers to a device that interacts with an aerosol-forming substrate to generate an aerosol. The aerosol generating device may interact with one or both of an aerosol generating article comprising an aerosol-forming substrate or a cartridge comprising an aerosol-forming substrate. In some examples, the aerosol generating device may heat the aerosol-forming substrate to promote release of volatile compounds from the substrate. An electrically operated aerosol generating device may include an atomizer, such as an electric heater, to heat the aerosol-forming substrate to form an aerosol.

[0339] As used herein, the term "aerosol generating system" refers to the combination of an aerosol generating device and an aerosol-forming substrate. When the aerosol-forming substrate forms part of an aerosol-generating article, the aerosol generating system refers to the combination of an aerosol generating device and an aerosol-generating article. In an aerosol generating system, the aerosol-forming substrate and the aerosol generating device cooperate to generate an aerosol.

[0340] As used herein, the term "tubular element" is used to refer to an elongated element that defines a lumen or airflow passage along its longitudinal axis. In particular, the term "tubular" is used herein to include any tubular element having a substantially cylindrical cross-section and defining at least one airflow passage that establishes uninterrupted fluid communication between the upstream end of the tubular element and the downstream end of the tubular element. However, it should be understood that alternative geometries of the tubular element may be possible.

[0341] As used herein, the terms "upstream" and "front" as well as "downstream" and "rear" are used to describe the relative position of a component or portion of a component of an aerosol generating article relative to the direction in which air flows through the aerosol generating article during use of the aerosol generating article. An aerosol generating article according to the present invention comprises a proximal end through which, in use, the aerosol leaves the article. The proximal end of the aerosol generating article may also be referred to as the mouth end or the downstream end. The mouth end is downstream of the distal end. The distal end of the aerosol generating article may also be referred to as the upstream end. Components or portions of components of an aerosol generating article may be described as being upstream or downstream of each other based on their relative position between the proximal end of the aerosol generating article and the distal end of the aerosol generating article. The front part of a component or portion of a component of an aerosol generating article is the portion at the end closest to the upstream end of the aerosol generating article. The rear part of a component or portion of a component of an aerosol generating article is the portion at the end closest to the downstream end of the aerosol generating article.

[0342] As used herein, the term "longitudinal" refers to a direction corresponding to the principal longitudinal axis of an aerosol-generating article, which direction extends between the upstream end and the downstream end of the aerosol-generating article.

[0343] The term "length" refers to the dimension of a component of an aerosol-generating article in the longitudinal direction. For example, it may be used to refer to the dimension of a strip or an elongated tubular element in the longitudinal direction.

[0344] As used herein in relation to the present invention, the term "transverse" is used to describe a direction perpendicular to the longitudinal direction. Unless otherwise stated, references to a "cross-section" of an aerosol-generating article or component of an aerosol-generating article refer to a cross-section.

[0345] As used herein, the term "proximal" refers to the user or mouth end of an aerosol-generating article and the term "distal" refers to the end opposite the proximal end.

[0346] Components of an aerosol-generating article according to the invention may be described as being upstream or downstream of each other based on their relative position between the proximal end of the aerosol-generating article and the distal end of the aerosol-generating article.

[0347] The aerosol-generating article comprises one or more susceptor elements. The one or more susceptor elements are included within the aerosol-forming substrate portion. For example, the one or more elongate susceptor elements may be arranged substantially longitudinally within the aerosol-forming substrate portion and in thermal contact with the aerosol-forming substrate.

[0348] As used herein, a "susceptor" or "susceptor element" refers to an element that becomes hot when subjected to an alternating magnetic field. This may be the result of eddy currents, hysteresis losses, or both eddy currents and hysteresis losses induced in the susceptor element. During use, the susceptor element is positioned in thermal contact or close thermal proximity to an aerosol-forming substrate received in an aerosol generating device or cartridge. In this way, the aerosol-forming substrate is heated by the susceptor such that an aerosol is formed.

[0349] The susceptor element may be formed from any material that can be heated by induction heating to a temperature sufficient to generate an aerosol from the aerosol-forming substrate.Preferably the susceptor element comprises metal or carbon.

[0350] Preferred susceptor elements may comprise or consist of a ferromagnetic material, such as a ferromagnetic alloy, ferritic iron, or a ferromagnetic steel or stainless steel. Suitable susceptor elements may be or comprise aluminium.

[0351] Suitable susceptor elements may include a non-metallic core having a metal layer disposed on the non-metallic core, such as a metal track formed on the surface of a ceramic core. The susceptor element may have an outer protective layer, such as a ceramic protective layer or a glass protective layer encapsulating the susceptor element. The susceptor element may include a protective coating formed of glass, ceramic or an inert metal formed on the core of the susceptor element material.

[0352] The susceptor element may be arranged in thermal contact with the aerosol-forming substrate of the aerosol-forming substrate portion of which the susceptor element is included. Thus, when the susceptor element heats up, the aerosol-forming substrate heats up and an aerosol is formed. Preferably, the susceptor element is arranged in direct physical contact with the aerosol-forming substrate, for example within the aerosol-forming substrate.

[0353] An aerosol generating device suitable for use with an aerosol generating article as described herein may comprise a heating chamber for receiving at least a portion of the aerosol generating article, and a heater for heating an aerosol-forming substrate portion of the aerosol generating article when the aerosol generating article is received within the heating chamber.

[0354] The aerosol generating device has a distal end and a mouth end.The aerosol generating device may comprise a body or housing.The body or housing of the aerosol generating device may define a device cavity for removably receiving an aerosol generating article at the mouth end of the device.

[0355] The device cavity may be referred to as a heating chamber of the aerosol-generating device. The device cavity may extend between a distal end and an oral end or a proximal end. The distal end of the device cavity may be a closed end, and the oral end or the proximal end of the device cavity may be an open end. The aerosol-generating article may be inserted into the device cavity or the heating chamber via the open end of the device cavity. The device cavity may be cylindrical so as to conform to the same shape of the aerosol-generating article.

[0356] The expression "received within" may refer to the fact that a component or element is fully or partially received within another component or element. For example, the expression "the aerosol-generating article is received within the device cavity" means that the aerosol-generating article is fully or partially received within the cavity of the aerosol-generating device. When the aerosol-generating article is received within the device cavity, the aerosol-generating article may be adjacent to the distal end of the device cavity. When the aerosol-generating article is received within the device cavity, the aerosol-generating article may be substantially proximate to the distal end of the device cavity. The distal end of the device cavity may be defined by an end wall.

[0357] The length of the device lumen may be between 15 mm and 80 mm, or between 20 mm and 70 mm, or between 25 mm and 60 mm, or between 25 mm and 50 mm.

[0358] The length of the device cavity (or heating chamber) may be equal to or greater than the length of the aerosol-forming substrate portion. The length of the device cavity may be equal to or greater than the combined length of the upstream section or element and the aerosol-forming substrate portion. Preferably, the length of the device cavity is such that when the aerosol-generating article is received by the aerosol-generating device, at least 75% of the length of the aerosol-forming substrate portion is inserted or received in the device cavity. More preferably, the length of the device cavity is such that when the aerosol-generating article is received by the aerosol-generating device, at least 80% of the length of the aerosol-forming substrate portion is inserted or received in the device cavity. More preferably, the length of the device cavity is such that when the aerosol-generating article is received by the aerosol-generating device, at least 90% of the length of the aerosol-forming substrate portion is inserted or received in the device cavity. This maximizes the length of the aerosol-forming substrate portion, and the aerosol-forming substrate can be heated along the length during use, thereby optimizing the generation of aerosol from the aerosol-forming substrate and reducing tobacco waste.

[0359] The length of the device cavity may be such that the downstream segment or a portion thereof is configured to protrude from the device cavity when the aerosol-generating article is received in the device cavity. The length of the device cavity may be such that a portion of the downstream segment (such as a hollow tubular cooling element or a downstream filter segment) is configured to protrude from the device cavity when the aerosol-generating article is received in the device cavity. The length of the device cavity may be such that a portion of the downstream segment (such as a hollow tubular cooling element or a downstream filter segment) is configured to be received in the device cavity when the aerosol-generating article is received in the device cavity.

[0360] When the aerosol-generating article is received in the device, at least 25% of the length of the downstream segment may be inserted or received in the device cavity.When the aerosol-generating article is received in the device, at least 30% of the length of the downstream segment may be inserted or received in the device cavity.

[0361] The diameter of the device lumen may be between 4 mm and 10 mm. The diameter of the device lumen may be between 5 mm and 9 mm. The diameter of the device lumen may be between 6 mm and 8 mm. The diameter of the device lumen may be between 6 mm and 7 mm.

[0362] The diameter of the device cavity may be substantially equal to or greater than the diameter of the aerosol-generating article.The diameter of the device cavity may be the same as the diameter of the aerosol-generating article so as to establish a close fit with the aerosol-generating article.

[0363] The device cavity may be configured to establish a tight fit with an aerosol generating article received in the device cavity. Tight fit may refer to a snug fit. The aerosol generating device may include a peripheral wall. The peripheral wall may define the device cavity or the heating chamber. The peripheral wall defining the device cavity may be configured to engage with the aerosol generating article received in the device cavity in a tight fit, such that when the aerosol generating article is received in the device, there is substantially no gap or empty space between the peripheral wall defining the device cavity and the aerosol generating article.

[0364] Such a tight fit may establish an air-tight fit or configuration between the device cavity and the aerosol-generating article received therein.

[0365] With such an airtight configuration, there will be substantially no gaps or empty spaces between the peripheral wall defining the device cavity and the aerosol-generating article for air to flow through.

[0366] The close fit with the aerosol-generating article may be established along the entire length of the device cavity or along a portion of the length of the device cavity.

[0367] The aerosol generating device may include an airflow channel extending between a channel inlet and a channel outlet. The airflow channel may be configured to establish fluid communication between the interior of the device cavity and the exterior of the aerosol generating device. The airflow channel of the aerosol generating device may be defined within a housing of the aerosol generating device to enable fluid communication between the interior of the device cavity and the exterior of the aerosol generating device. When the aerosol generating article is received in the device cavity, the airflow channel may be configured to provide airflow into the article so as to deliver the generated aerosol to a user who draws from the mouth end of the article.

[0368] The airflow passage of the aerosol generating device may be defined within or by the peripheral wall of the housing of the aerosol generating device. In other words, the airflow passage of the aerosol generating device may be defined within the thickness of the peripheral wall or by the inner surface of the peripheral wall, or a combination of both. The airflow passage may be partially defined by the inner surface of the peripheral wall and may be partially defined within the thickness of the peripheral wall. The inner surface of the peripheral wall defines the peripheral boundary of the device cavity.

[0369] The airflow channel of the aerosol generating device may extend from an inlet located at the mouth or proximal end of the aerosol generating device to an outlet located distal to the mouth end of the device.The airflow channel may extend in a direction parallel to the longitudinal axis of the aerosol generating device.

[0370] The heater may be any suitable type of heater. Preferably, in the present invention, the heater is an external heater.

[0371] Preferably, the heater is located at or around the periphery of the heating chamber.

[0372] Preferably, the heater externally heats the aerosol-forming substrate portion when the aerosol-generating article is received in the aerosol-generating device.Such an external heater may confine the aerosol-generating article when the aerosol-generating article is inserted into or received in the aerosol-generating device.

[0373] In some embodiments, the heater is arranged to heat the outer surface of the aerosol-forming substrate portion.

[0374] In some embodiments, the heater is arranged to be inserted into the aerosol-forming substrate when the aerosol-forming substrate is received in the cavity.

[0375] The heater may be positioned within the device cavity or within the heating chamber.

[0376] The heater may include at least one heating element. The at least one heating element may be any suitable type of heating element. In some embodiments, the device includes only one heating element. In some embodiments, the device includes multiple heating elements.

[0377] Suitable materials for forming at least one resistive heating element include, but are not limited to, semiconductors such as doped ceramics, electrically "conductive" ceramics (e.g., molybdenum disilicide), carbon, graphite, metals, metal alloys, and composite materials made of ceramic materials and metallic materials. Such composite materials may include doped or undoped ceramics. Examples of suitable doped ceramics include doped silicon carbide. Examples of suitable metals include titanium, zirconium, tantalum, and platinum group metals. Examples of suitable metal alloys include stainless steel, alloys containing nickel, cobalt, chromium, aluminum-titanium-zirconium, hafnium, niobium, molybdenum, tantalum, tungsten, tin, gallium, manganese, and iron, and superalloys based on nickel, iron, cobalt, stainless steel, Timetal®, and iron-manganese-aluminum-based alloys.

[0378] In some embodiments, at least one resistive heating element comprises one or more stamped portions of a resistive material such as stainless steel. Alternatively, at least one resistive heating element may comprise a heating wire or filament, such as Ni-Cr (nickel-chromium), platinum, tungsten or alloy wire.

[0379] In some embodiments, the at least one heating element comprises an electrically insulating substrate, wherein the at least one resistive heating element is disposed on the electrically insulating substrate.

[0380] The electrically insulating substrate may include any suitable material. For example, the electrically insulating substrate may include one or more of paper, glass, ceramic, anodized metal, coated metal, and polyimide. The ceramic may include mica, aluminum oxide (Al2O3), or zirconium oxide (ZrO2). Preferably, the electrically insulating substrate has a thermal conductivity of less than or equal to about 40 W / m·Kelvin, preferably less than or equal to about 20 W / m·Kelvin, and ideally less than or equal to about 2 W / m·Kelvin.

[0381] The heater may comprise a heating element comprising a rigid electrically insulating substrate having one or more conductive tracks or wires disposed on its surface. The size and shape of the electrically insulating substrate may allow it to be inserted directly into the aerosol-forming substrate. If the electrically insulating substrate is not rigid enough, the heating element may comprise additional reinforcing means. An electric current may be passed through the one or more conductive tracks to heat the heating element and the aerosol-forming substrate.

[0382] In some embodiments, the heater comprises an induction heating device. The induction heating device may include an inductor coil and a power supply configured to provide a high-frequency oscillating current to the inductor coil. As used herein, a high-frequency oscillating current means an oscillating current having a frequency between about 500 kHz and about 30 MHz. Advantageously, the heater may include a DC / AC inverter for converting a DC current supplied by a DC power supply into an alternating current. The inductor coil may be arranged to generate a high-frequency oscillating electromagnetic field when receiving the high-frequency oscillating current from the power supply. The inductor coil may be arranged to generate a high-frequency oscillating electromagnetic field in a device cavity. In some embodiments, the inductor coil may substantially define the device cavity. The inductor coil may extend at least partially along the length of the device cavity.

[0383] The heater may comprise an inductive heating element. The inductive heating element may be a susceptor element. The susceptor element may be arranged such that when the aerosol generating article is received in the cavity of the aerosol generating device, the oscillating electromagnetic field generated by the inductor coil induces a current in the susceptor element, thereby causing the susceptor element to heat up. In these embodiments, the aerosol generating device is preferably capable of generating a fluctuating electromagnetic field having a magnetic field strength (H field strength) between 1 kiloamperes per meter and 5 kiloamperes per meter (kA m), preferably between 2 kA / m and 3 kA / m, for example about 2.5 kA / m. Preferably, the electrically operated aerosol generating device is capable of generating a fluctuating electromagnetic field having a frequency between 1 MHz and 30 MHz, for example between 1 MHz and 10 MHz, for example between 5 MHz and 7 MHz.

[0384] In these embodiments, the susceptor element is preferably positioned in contact with the aerosol-forming substrate. In some embodiments, the susceptor element is positioned in the aerosol generating device. In these embodiments, the susceptor element may be positioned in a cavity. The aerosol generating device may include only one susceptor element. The aerosol generating device may include a plurality of susceptor elements. In some embodiments, the susceptor element is preferably arranged to heat the outer surface of the aerosol-forming substrate.

[0385] The susceptor element may comprise any suitable material as described above with respect to the susceptor element incorporated within the aerosol-forming substrate portion.

[0386] In some embodiments, the aerosol generating device may comprise at least one resistive heating element and at least one inductive heating element. In some embodiments, the aerosol generating device may comprise a combination of resistive heating elements and inductive heating elements.

[0387] During use, the heater can be controlled to operate within a limited operating temperature range below the maximum operating temperature. An operating temperature range between about 150 degrees Celsius and about 300 degrees Celsius in the heating chamber (or device cavity) is preferred. The operating temperature range of the heater may be between about 150 degrees Celsius and about 250 degrees Celsius.

[0388] The aerosol generating device may include a power source. The power source may be a DC power source. In some embodiments, the power source is a battery. The power source may be a nickel metal hydride battery, a nickel cadmium battery, or a lithium-based battery, such as a lithium cobalt battery, a lithium iron phosphate battery, or a lithium polymer battery. However, in some embodiments, the power source may be another form of charge storage device, such as a capacitor. The power source may need to be recharged and may have a capacity that allows storage of energy sufficient for one or more user operations (e.g., one or more aerosol generating experiences).

[0389] A non-exhaustive list of non-limiting examples is provided below.Any one or more features of these examples may be combined with any one or more features of another example, embodiment or aspect described herein.

[0390] Example E1: An aerosol-generating article comprising

[0391] a central axis extending centrally along the longitudinal direction of the aerosol-generating article;

[0392] an aerosol-forming substrate portion housing the susceptor and an aerosol-forming substrate at least partially defining the susceptor; and

[0393] a substrate wrapper at least partially defining the aerosol-forming substrate portion and forming an overlapping region of overlapping end portions of the substrate wrapper,

[0394] wherein the matrix wrapper has a thickness of 50 microns or greater,

[0395] wherein the substrate wrapper comprises one or more layers having the same length in a direction parallel to the central axis, and

[0396] wherein the susceptor comprises a flat planar susceptor portion oriented such that

[0397] A first straight line perpendicular to the flat plane of the flat planar susceptor portion and

[0398] The angle between a second straight line perpendicular to the central axis and extending from the central axis to a position in the overlap region

[0399] Between 0 and 25 degrees.

[0400] Example E2: An aerosol-generating article according to Example El, wherein the combination of all of the one or more layers of the substrate wrapper having the same length defines an overall thickness of the substrate wrapper of 50 microns or greater.

[0401] Example E3: An aerosol-generating article according to Example El or Example E2, wherein at least one of the one or more layers of the substrate wrapper has an individual thickness of 50 micrometers or greater.

[0402] Example E4: An aerosol-generating article according to Example E3, wherein each of the one or more layers of the substrate wrapper having the same length has an individual thickness of 50 micrometers or greater.

[0403] Example E5: An aerosol-generating article according to any of the preceding examples, wherein the substrate wrapper does not extend beyond a longitudinal end of the aerosol-forming substrate portion in a longitudinal direction of the aerosol-generating article.

[0404] Example E6: An aerosol-generating article comprising

[0405] a central axis extending centrally along the longitudinal direction of the aerosol-generating article;

[0406] an aerosol-forming substrate portion housing the susceptor and an aerosol-forming substrate at least partially defining the susceptor; and

[0407] a substrate wrapper at least partially defining the aerosol-forming substrate portion and forming an overlapping region of overlapping end portions of the substrate wrapper,

[0408] wherein the matrix wrapper has a thickness of 50 microns or greater,

[0409] wherein the substrate wrapper does not extend beyond an end of the aerosol-forming substrate portion in a direction parallel to the central axis, and

[0410] wherein the susceptor comprises a flat planar susceptor portion oriented such that

[0411] A first straight line perpendicular to the flat plane of the flat planar susceptor portion and

[0412] The angle between a second straight line perpendicular to the central axis and extending from the central axis to a position in the overlap region

[0413] Between 0 and 25 degrees.

[0414] Example E7: An aerosol-generating article according to any of the preceding examples, wherein the substrate wrapper has a thickness of 60 microns or greater, preferably 70 microns or greater, more preferably 75 microns or greater, more preferably 90 microns or greater, more preferably 120 microns or greater, more preferably 145 microns or greater.

[0415] Example E8: An aerosol-generating article according to Example E7, wherein the substrate wrapper has a thickness of between 140 and 160 microns.

[0416] Example E9: An aerosol-generating article according to any of the preceding examples, wherein the ratio of the substrate wrapper thickness to the aerosol-forming substrate portion diameter is in the range of about 1:120 to about 1:20, or about 1:100 to about 1:30, or about 1:80 to about 1:35, or about 1:60 to about 1:40.

[0417] Example E10: An aerosol-generating article according to any of the preceding examples, wherein the density of the substrate packaging is 800 kg / m3 or less, preferably 750 kg / m3 or less, more preferably 700 kg / m3 or less, more preferably 650 kg / m3 or less, more preferably 600 kg / m3 or less, more preferably 550 kg / m3 or less, more preferably 500 kg / m3 or less, more preferably 450 kg / m3 or less, more preferably 400 kg / m3 or less, more preferably 350 kg / m3 or less, more preferably about 320 kg / m3.

[0418] Example E11: An aerosol-generating article according to any of the preceding examples, wherein the substrate wrapper has a basis weight of less than 60 grams per square meter.

[0419] Example E12: An aerosol-generating article according to example E11, wherein the substrate wrapper has a basis weight greater than 28 g / m2 and less than 50 g / m2.

[0420] Example E13: An aerosol-generating article according to any of the preceding examples, wherein the substrate wrapper has a thickness greater than 145 microns and a density of 400 kg / m3 or less.

[0421] Example E14: An aerosol-generating article according to any of the preceding examples, wherein the substrate wrapper is perforated.

[0422] Example E15: An aerosol-generating article according to any of the preceding examples, wherein the substrate wrapper is convex.

[0423] Example E16: An aerosol-generating article according to any of Examples E1 to E13, wherein the substrate wrapper has a uniform thickness that does not vary by more than about 30 microns, or more than about 20 microns, or more than about 10 microns, or more than about 5 microns at any point.

[0424] Example E17: An aerosol-generating article according to any of the preceding examples, wherein the substrate wrapper exhibits a permeability of the wrapper in the range of 4000 CORESTA Units to 4800 CORESTA Units, preferably 4200 CORESTA Units to 4600 CORESTA Units, more preferably 4300 CORESTA Units to 4500 CORESTA Units, wherein the permeability of the cigarette paper is determined using the international standard test method ISO 2965:2009 and the results are expressed in cubic centimeters per minute per square centimeter and are referred to as "CORESTA units".

[0425] Example E18: An aerosol-generating article according to any of the preceding examples, wherein the substrate wrapper has a roughness of between about 50 Bekk seconds and about 1000 Bekk seconds, preferably between about 100 Bekk seconds and about 200 Bekk seconds.

[0426] Example E19: An aerosol-generating article according to any of the preceding examples, wherein the substrate wrapper extends along the entire length of the aerosol-forming substrate portion in a direction parallel to the longitudinal direction of the aerosol-generating article.

[0427] Example E20: An aerosol-generating article according to any of the preceding examples, wherein the substrate wrapper comprises one or more of paperboard, plastic, and metal foil.

[0428] Example E21: An aerosol-generating article according to any of the preceding examples, wherein the substrate wrapper comprises a cellulosic material such as one or more of paper, wood, textiles, natural fibers, and man-made fibers.

[0429] Example E22: An aerosol-generating article according to any of the preceding examples, wherein the substrate wrapper comprises a paper layer.

[0430] Example E23: An aerosol-generating article according to any one of the preceding examples, wherein the substrate wrapper comprises a laminated sheet, preferably, wherein the substrate wrapper is made of a laminated sheet, more preferably, wherein the laminated sheet is a laminate of a paper layer and an aluminum layer.

[0431] Example E24: An aerosol-generating article according to any of the preceding examples, wherein the substrate wrapper is formed from a single continuous sheet, preferably a single sheet of paper.

[0432] Example E25: An aerosol generating article according to any one of Examples E1 to E23, wherein the substrate packaging is a substrate packaging system formed by a first individual packaging sheet and a second individual packaging sheet, wherein the first individual packaging sheet includes a first overlapping area formed by overlapping relative end portions of the first individual packaging sheet, wherein the second individual packaging sheet includes a second overlapping area formed by overlapping relative end portions of the second individual packaging sheet, and wherein the first overlapping area and the second overlapping area are arranged at opposite sides of the flat planar receptor portion.

[0433] Example E26: An aerosol-generating article according to any one of the preceding examples, wherein the total length of the aerosol-forming substrate portion is 11 mm or less.

[0434] Example E27: An aerosol-generating article according to any one of the preceding examples, wherein the aerosol-forming substrate is provided in the form of a gathered sheet of homogenised tobacco material.

[0435] Example E28: An aerosol-generating article according to example E27, wherein the sheet of homogenised tobacco material has a grammage of less than 210 g / m2, preferably less than 200 g / m2, more preferably about 192 g / m2.

[0436] Example E29: An aerosol-generating article according to example E27 or example E28, wherein the sheet of homogenised tobacco material has a thickness greater than 215 microns, preferably greater than 220 microns, more preferably about 228 microns.

[0437] Example E30: An aerosol-generating article according to any one of Examples E27 to E29, wherein the sheet of homogenized tobacco material is a cast sheet, and wherein, before the casting process, the homogenized tobacco material comprises: tobacco particles having an average particle size (D95) greater than 50 microns, preferably between greater than 50 microns and less than 100 microns, more preferably between 60 microns and 80 microns, more preferably between 65 microns and 75 microns, more preferably about 70 microns.

[0438] Example E31: An aerosol-generating article according to any one of the preceding examples, wherein the aerosol-forming substrate comprises tobacco material, about 1% to about 5% binder, and about 10% to about 30% glycerol by dry weight.

[0439] Example E32: An aerosol-generating article according to any of the preceding examples, wherein the aerosol-forming substrate portion defines a substantially cylindrical shape having a diameter in the range of about 6.8 mm to about 7.1 mm, or about 6.8 mm to about 7.0 mm.

[0440] Example E33: An aerosol-generating article according to any of the preceding examples, wherein the angle is between 0 and 20 degrees, preferably between 0 and 15 degrees, more preferably between 0 and 10 degrees, more preferably between 0 and 5 degrees.

[0441] Example E34: An aerosol-generating article according to any of the preceding examples, wherein the overlap region extends along less than 15%, preferably less than 10%, more preferably less than 5% of the circumference of the aerosol-forming substrate portion.

[0442] Example E35: An aerosol-generating article according to any of the preceding examples, wherein the second straight line extends from the central axis to the middle of the overlap region.

[0443] Example E36: ​​An aerosol-generating article according to any of the preceding examples, wherein the second straight line extends from the central axis to a glue line disposed in the overlap region.

[0444] Example E37: An aerosol-generating article according to any of the preceding examples, wherein the thickness of the substrate wrapper is measured in an area that is not the overlap area.

[0445] Example E38: An aerosol-generating article according to any of the preceding examples, wherein the susceptor is a flat planar susceptor strip which is elongated in a direction parallel to the central axis, preferably wherein the susceptor strip has a length of 5 mm to 15 mm and a width of at least about 1 mm, preferably at least about 2 mm.

[0446] Example E39: An aerosol-generating article according to any one of the preceding examples, wherein the susceptor is centrally arranged within the aerosol-forming substrate portion.

[0447] Example E40: An aerosol-generating article according to any one of the preceding examples, wherein the length of the overlapping region in a direction parallel to the central axis is equal to or greater than the length of the susceptor, and

[0448] Wherein in the direction perpendicular to the central axis, the width of the overlapping area is equal to or smaller than the width of the susceptor.

[0449] Example E41: An aerosol-generating article according to any of the preceding examples, wherein the susceptor comprises a metal material, preferably aluminum.

[0450] Example E42: A package comprising a plurality of aerosol-generating articles, wherein each aerosol-generating article in the package is an aerosol-generating article according to any one of the preceding examples.

[0451] Example E42: An aerosol generating system comprising an aerosol generating article according to any of Examples E1 to E41 and an aerosol generating device, the aerosol generating device comprising a heating chamber, the heating chamber being configured for at least partially inserting the aerosol generating article into the heating chamber.

[0452] Features described with respect to one embodiment may be equally applicable to other embodiments of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0453] The present invention will be further described, by way of example only, with reference to the accompanying drawings, in which:

[0454] Figure 1 a and 1b show aerosol generating articles;

[0455] Figure 2 a to 2c show aerosol generating articles;

[0456] Figure 3 a and 3b show aerosol generating articles;

[0457] Figure 4 4a and 4b show aerosol-generating articles. DETAILED DESCRIPTION

[0458] Figure 1 a shows an aerosol generating article in a cross-sectional view. The aerosol generating article includes a mouth end filter 10 positioned at the proximal end of the article. The article also includes a PLA (polylactic acid) rod 12, a hollow acetate tube 14 and an aerosol forming substrate portion 16, which includes an aerosol forming substrate, such as a collection sheet of homogenized tobacco. The article is defined by a tipping wrapper 18. The article also includes a flat planar susceptor 20, which is arranged in the aerosol forming substrate portion 16 and is defined by the aerosol forming substrate. The central axis 22 extends centrally along the longitudinal direction of the aerosol generating article. The aerosol forming substrate portion 16 is defined by a substrate wrapper 24. The substrate wrapper has a thickness of at least 50 microns. The substrate wrapper 24 does not extend beyond the longitudinal end of the aerosol forming substrate portion 16 in a direction parallel to the central axis 22.

[0459] Figure 1 b shows Figure 1 The product of a is along the Figure 1 Section along line XX shown in a. Figure 1 b shows an overlapping area of ​​the matrix wrapper 24 forming overlapping opposite end portions of the matrix wrapper 24. The width of the overlapping area is indicated by the double ended arrow 26. In the middle of the overlapping area, a glue line 28 may be present.

[0460] A first straight line 30 is indicated as being perpendicular to the two opposing flat planes 21 of the flat planar susceptor 20. A second straight line 32 is indicated as being perpendicular to the central axis 22 and extending from the central axis 22 to a location in the overlap region, in this case, to the glue line 28 in the middle of the overlap region. The first straight line 30 and the second straight line 32 are substantially collinear, and the angle between the first line and the second line is about 0 degrees.

[0461] In the illustrated embodiment, the susceptor 20 is positioned in the aerosol-forming substrate portion 16 substantially centrally. Therefore, the susceptor can substantially uniformly heat the surrounding aerosol-forming substrate during use. Meanwhile, the flat plane susceptor 20 is oriented so that when centered, the flat plane susceptor 20 is positioned as far away from the glue line 28 as possible. Therefore, the accidental heating of glue can be reduced. In addition, the susceptor is positioned away from the pit 33. The pit 33 indicates the area beside the edge of the underlying end portion of the substrate wrapper 24 in the overlapping area. In particular, when using a thick substrate wrapper 24 such as thicker than 50 microns, the thick edge of the underlying end portion of the substrate wrapper 24 will produce a larger pit 33. Since the pit is shielded by the edge of the inner wrapper layer, there is no or only a little aerosol-forming substrate to be positioned in the pit 33. Because there is no or only a little aerosol-forming substrate in the pit 33, it is not very meaningful to heat this area. Therefore, when the susceptor 20 is positioned away from the pit 33, the unnecessary heating of the pit 33 can be reduced. Thus, energy-efficient aerosol generating articles may be obtained.

[0462] The flat planar surfaces 21 are arranged generally parallel to the overlap region. The generally parallel aligned flat planar susceptors 20 may act as a stabilizing underlayer when opposing end portions of the substrate wrapper 24 are pressed onto each other to close the overlap region during manufacture of the aerosol-generating article.

[0463] Figure 2 a is similarly shown Figure 1 The product of a is along the Figure 1 The section along line XX shown in a, except that the tipping wrapper 18 and the glue line 28 are absent.

[0464] and Figure 1 b, the angle of the first straight line 30 does not change because the orientation of the flat planar susceptor 20 does not change.

[0465] The second straight line 32 is defined as being perpendicular to the central axis 22 and extending from the central axis 22 to a position in the overlapping region. Figure 1 b is different. Figure 2 In a, the overlap region is not located exactly in the middle of the overlap region. Figure 2In a, the second straight line 32 is drawn to extend from the central axis 22 to a peripheral position in the overlap region. Thus, there is an angle 34 of about 10 degrees between the first line 30 and the second line 32.

[0466] Figure 2 b shows an alternative embodiment, which is Figure 1 The difference of the embodiment b is that the flat plane susceptor 20 is slightly offset from the central axis 22 and tilted by about 10 degrees. This may be caused, for example, by manufacturing tolerances. Therefore, the first straight line 30 perpendicular to the two relatively flat planes 21 is also compared to Figure 1 b is inclined at about 10 degrees. The second straight line 32 is as follows Figure 1 Thus, there is an angle 34 of about 10 degrees between the first line 30 and the second line 32.

[0467] It should be noted that when Figure 2 b, when a different configuration of the second line 32 is used, for example, the second line 32 is limited to extend to the peripheral portion of the overlap area (such as Figure 2 a), then in Figure 2 In the embodiment of FIG. 1 , an angle 34 of about 20 degrees or about 0 degrees is created between the first line 30 and the second line 32, depending on which of the two peripheral portions of the overlapping area is selected. Figure 2 Whichever configuration is chosen for the second straight line 32 in b, the angle 34 will always be less than 25 degrees.

[0468] Figure 2 c shows the orientation of a flat planar susceptor 20 not according to the present invention. Figure 1 b is tilted by about 90 degrees. Therefore, the first straight line 30 is also rotated by about 90 degrees. The angle 34 between the first straight line 30 and the second straight line 32 is about 90 degrees. It should be noted that if Figure 2 c using a different configuration of the second line 32, such as the second line 32 extending to the outer peripheral portion of the overlap region (eg Figure 2 a) is constructed, then in Figure 2 c, the first line 30 and the second line 32 form an angle 34 of about 80 degrees. Figure 2 Whichever configuration is chosen for the second straight line 32 in c, the angle 34 will always be approximately 80 to 90 degrees.

[0469] Figure 2 The double-ended arrow 36 in c indicates that when Figure 1 When compared with b, Figure 2 The susceptor 20 in the embodiment of c is closer to the glue line 28. Figure 2 c when compared with the embodiment, Figure 1 b can reduce the accidental heating of the glue line. In addition, when Figure 1When compared with b, Figure 2 The susceptor 20 in the embodiment of c is closer to the pit 33. Figure 2 c when compared with the embodiment, Figure 1 Embodiment b can reduce unnecessary heating of the dimple 33 .

[0470] Figure 3 a shows an aerosol-generating article in a cross-sectional view. Figure 3 The article in a comprises a mouth end filter 10, a thin hollow acetate tube 38, a hollow acetate tube 40, an aerosol-forming substrate portion 16 and a front filter segment 42. The mouth end filter 10, the thin hollow acetate tube 38 and the hollow acetate tube 40 form a downstream section downstream of the aerosol-forming substrate portion 16. The front filter segment 42 forms an upstream section upstream of the aerosol-forming substrate portion 16.

[0471] The aerosol-forming substrate portion 16 comprises a flat planar susceptor 20 defined by an aerosol-forming substrate. The aerosol-forming substrate portion 16 is defined by a thick substrate wrapper 24. Figure 1 As shown in b, the susceptor 20 is aligned with the overlapping area of ​​the substrate wrapper 24.

[0472] The front filter segment 42 may be a filter filter segment. The distal portion of the article is defined by the tipping wrapper 18, and the proximal portion is defined by the mouthpiece wrapper 44. A row of circumferential ventilation holes 46 is provided in the area where the mouthpiece wrapper 44 overlaps the tipping wrapper 18. The ventilation holes 46 may be provided in one or both of the thin hollow acetate tube 38, the mouthpiece wrapper 44, and the tipping wrapper 18.

[0473] The outer diameter of the article may be about 7 mm, preferably 7.1 mm. The total length of the article may be about 45 mm. In one embodiment, the length of the mouth end filter 10 is about 12 mm, the length of the thin hollow acetate tube 38 is about 9 mm, the length of the hollow acetate tube 40 is about 8 mm, the length of the aerosol-forming substrate portion 16 is about 11 mm, and the length of the front filter segment 42 is about 5 mm.

[0474] Figure 3 b shows an aerosol-generating article in a cross-sectional view. Figure 3 The aerosol-generating article of b may have an overall length of about 75 mm and an outer diameter of about 6.7 mm.

[0475] Figure 3The article of claim 1 comprises a hollow mouthpiece tube 48 at the proximal end of the article, such as a hollow cylindrical tube made of cellulose acetate. The hollow mouthpiece tube 48 defines an inner cavity extending from the upstream end of the hollow mouthpiece tube 48 to the downstream end of the mouth end filter 10. The inner cavity is substantially empty, and thus substantially unrestricted airflow is achieved along the inner cavity. The hollow mouthpiece tube 48 does not substantially affect the overall RTD of the aerosol generating article. The length of the hollow mouthpiece tube 48 may be about 6 mm, and the outer diameter may be about 6.7 mm. The wall thickness of the hollow mouthpiece tube 48 may be about 1 mm.

[0476] The article further comprises a mouth end filter 10. The mouth end filter 10 may have a length of about 10 millimeters. The outer diameter of the mouth end filter 10 may be about 6.7 millimeters.

[0477] The article further comprises a hollow tube 50, such as a paperboard tube. The hollow tube 50 does not substantially affect the overall RTD of the aerosol generating article. In more detail, the RTD of the hollow tube 50 is about 0 mm H2O. The hollow tube 50 may have a length of about 25 mm or more, an outer diameter of about 6.7 mm, and an inner diameter of about 6.2 mm. Thus, the thickness of the outer peripheral wall of the hollow tube 50 may be about 0.25 mm.

[0478] The hollow tube 50 may comprise one or more rows of ventilation holes 46 arranged circumferentially around the hollow tube 50 in a cross section that is substantially perpendicular to the longitudinal axis of the article.The ventilation level of the aerosol-generating article may be about 75%.

[0479] At the distal end, the article comprises an aerosol-forming substrate portion 16 comprising a flat planar susceptor 20 defined by an aerosol-forming substrate. The aerosol-forming substrate portion 16 is defined by a thick substrate wrapper 24. Figure 1 As shown in FIG. 1 , the susceptor 20 is aligned with the overlap area of ​​the substrate wrapper 24. In addition, one or more outer wrappers 18, 44 that define at least a portion of the aerosol generating article may be provided. One or more outer wrappers 18, 44 may also include ventilation holes 46. If present, the outer wrapper 44 may overlie the portion of the outer wrapper 18 overlying the hollow tube 50. In this way, the outer wrapper 44 effectively links the mouth end filter 10 to the remaining components of the article. The width of the outer wrapper 44 may be about 26 millimeters.

[0480] In one embodiment, Figure 3 The aerosol-generating article of b has an overall length of about 80 mm and an outer diameter of about 6.5 mm, the hollow tube 50 has a length of about 25 mm or greater, the mouth end filter 10 has a length of about 10 mm, and the length of the hollow mouthpiece tube 48 is about 6 mm.

[0481] Figure 4a shows an aerosol-generating article in cross-sectional view, comprising an aerosol-forming substrate portion 16 at its distal end. The aerosol-forming substrate portion 16 comprises a flat planar susceptor 20 defined by an aerosol-forming substrate. The aerosol-forming substrate portion 16 is defined by a thick substrate wrapper 24. Figure 1 As shown in b, the susceptor 20 is aligned with the overlapping area of ​​the substrate wrapper 24.

[0482] The downstream section includes a hollow tube 50 and a mouth end filter 10. The hollow tube 50 may include one or more rows of ventilation holes 46. The upstream section includes a front filter segment 42. The front filter segment 42 may be provided in the form of a cylindrical rod of cellulose acetate tow, or may be provided in the form of a hollow cylindrical rod of cellulose acetate tow having a wall thickness of about 1 mm.

[0483] The aerosol generating article may have an overall length of about 45 mm and an outer diameter of about 7.2 mm. The overall length of the downstream section may be about 20 mm to 30 mm. The length of the mouth end filter 10 may be about 7 mm. The overall length of the upstream section may be about 5 mm.

[0484] Figure 4 b shows in cross-sectional view an aerosol-generating article comprising an aerosol-forming substrate portion 16 comprising a flat planar susceptor 20 defined by an aerosol-forming substrate. The aerosol-forming substrate portion 16 is defined by a thick substrate wrapper 24. Figure 1 As shown in b, the susceptor 20 is aligned with the overlap area of ​​the substrate wrapper 24. The downstream section includes the hollow tube 50 and the mouth end filter 10. The hollow tube 50 may include one or more rows of ventilation holes 46.

[0485] Figure 4 The aerosol generating article of b may have an overall length of about 45 mm and an outer diameter of about 7.2 mm. The hollow tube 50 may have a length of about 20 to 30 mm, an outer diameter of about 7.2 mm, and an inner diameter of about 6.7 mm. Therefore, the thickness of the outer peripheral wall of the hollow tube 50 is about 0.25 mm. The mouth-end filter 10 may have a length of about 5 mm to 7 mm and an outer diameter of about 7.2 mm. The mouth-end filter 10 may include a low-density cellulose acetate filter segment. The RTD of the mouth-end filter 10 may be about 8 mm of water column. The mouth-end filter 10 may be wrapped separately by a rod wrapper (not shown). In addition, one or more outer wrappers 18, 44 that define at least a portion of the aerosol generating article may be provided.

Claims

1. An aerosol generating article comprising a central axis extending centrally along the longitudinal direction of the aerosol-generating article; an aerosol-forming substrate portion housing a susceptor and an aerosol-forming substrate at least partially defining the susceptor; as well as a substrate wrapper at least partially defining the aerosol-forming substrate portion and forming an overlapping region of overlapping end portions of the substrate wrapper, wherein the matrix wrapper has a thickness of 50 microns or greater, wherein the substrate wrapper comprises one or more layers having the same length in a direction parallel to the central axis, and wherein the susceptor comprises a flat planar susceptor portion oriented such that A first straight line perpendicular to the flat plane of the flat planar susceptor portion and The angle between a second straight line perpendicular to the central axis and extending from the central axis to a position in the overlap region Between 0 and 25 degrees.

2. An aerosol-generating article according to claim 1, wherein the angle is between 0 and 20 degrees, preferably between 0 and 15 degrees, more preferably between 0 and 10 degrees, more preferably between 0 and 5 degrees.

3. An aerosol-generating article according to claim 1 or claim 2, wherein the substrate wrapper has a thickness of 60 microns or greater, preferably 70 microns or greater, more preferably 75 microns or greater, more preferably 90 microns or greater, more preferably 120 microns or greater, more preferably 145 microns or greater.

4. An aerosol-generating article according to claim 3, wherein the substrate wrapper has a thickness of between 140 microns and 160 microns.

5. An aerosol-generating article according to any of the preceding claims, wherein the ratio of the substrate wrapper thickness to the diameter of the aerosol-forming substrate portion is in the range of about 1:120 to about 1:20, or about 1:100 to about 1:30, or about 1:80 to about 1:35, or about 1:60 to about 1:

40.

6. An aerosol-generating article according to any one of the preceding claims, wherein the overlap region extends along less than 15%, preferably less than 10%, more preferably less than 5% of the circumference of the aerosol-forming substrate portion.

7. An aerosol-generating article according to any one of the preceding claims, wherein the second straight line extends from the central axis to the middle of the overlap region.

8. An aerosol-generating article according to any one of the preceding claims, wherein the second straight line extends from the central axis to a glue line provided in the overlap region.

9. An aerosol-generating article according to any one of the preceding claims, wherein the thickness of the substrate wrapper is measured in an area other than the overlap area.

10. An aerosol-generating article according to any one of the preceding claims, wherein the susceptor is a flat planar susceptor strip which is elongated in a direction parallel to the central axis, preferably wherein the susceptor strip has a length of 5 mm to 15 mm and a width of at least about 1 mm, preferably at least about 2 mm.

11. An aerosol-generating article according to any one of the preceding claims, wherein the susceptor is arranged centrally within the aerosol-forming substrate portion.

12. An aerosol-generating article according to any one of the preceding claims, wherein the length of the overlap region in a direction parallel to the central axis is equal to or greater than the length of the susceptor, and Wherein in the direction perpendicular to the central axis, the width of the overlapping area is equal to or smaller than the width of the susceptor.

13. An aerosol-generating article according to any one of the preceding claims, wherein the susceptor comprises a metallic material, preferably aluminium.

14. A package comprising a plurality of aerosol-generating articles, wherein each aerosol-generating article in the package is an aerosol-generating article according to any one of the preceding claims.

15. An aerosol generating system, comprising an aerosol generating article according to any one of claims 1 to 13 and an aerosol generating device, the aerosol generating device comprising a heating chamber, the heating chamber being configured for at least partially inserting the aerosol generating article into the heating chamber.

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