Aerosol-generating article with planar frame

Abstract

An aerosol-generating article (1) for use with an aerosol-generating device to form an inhalable aerosol, the aerosol-generating article comprising a planar frame (4) and an aerosol-generating substrate (5, 6). The planar frame comprises: a top surface (401), a bottom surface (407) and lateral sides (403, 404, 405, 406); an inlet (43) disposed on the lateral side (406); an outlet (44) disposed on a lateral side (405) opposite the inlet; a recess (45) between the inlet and the outlet; and an opening (46) on the top surface. An aerosol-generating substrate (5, 6) is disposed in the recess (45), and the aerosol-generating substrate (5, 6) is smaller than the opening (46).

Description

Technical Field

[0001] The present disclosure relates to an aerosol-generating article and an aerosol-generating system including an aerosol-generating device and an aerosol-generating article. Background Art

[0002] Some known aerosol-generating systems include an aerosol-generating device having a power source (such as a battery), a controller, and a heating element for heating an aerosol-generating substrate. In some instances, the aerosol-generating substrate includes a tobacco strip or rod disposed in the aerosol-generating article. In use, the aerosol-generating article is inserted into a cavity of the aerosol-generating device, and the heating element penetrates through the aerosol-generating substrate or is disposed around the exterior of the aerosol-generating substrate. Electric power is supplied from the power source to the heating element to heat the aerosol-generating substrate, and the volatile components of the aerosol-generating substrate are vaporized and released and condensed to form an aerosol that can be inhaled by a user. In some such aerosol-generating systems, the aerosol-generating article resembles a conventional cigarette and has a similar cylindrical rod-like configuration. Such known aerosol-generating articles are neither easy to manufacture nor easy for a user to personalize.

[0003] There is a desire to provide an improved aerosol-generating article for use with an aerosol-generating device. Summary of the Invention

[0004] According to the present disclosure, there is provided an aerosol-generating article for use with an aerosol-generating device to form an inhalable aerosol. The aerosol-generating article may include a planar frame. The aerosol-generating article may include an aerosol-generating substrate. The planar frame may include a top surface. The planar frame may include a bottom surface. The planar frame may include lateral sides. The planar frame may include an inlet. The inlet may be provided on a lateral side. The planar frame may include an outlet. The outlet may be provided on a lateral side. The outlet may be provided on a lateral side opposite to the inlet. The planar frame may include a recess. The recess may be between the inlet and the outlet. The planar frame may include an opening. The opening may be on the top surface. The aerosol-generating substrate may be disposed in the recess. The aerosol-generating substrate may be smaller than the opening.

[0005] According to the present disclosure, there is provided an aerosol-generating article for use with an aerosol-generating device to form an inhalable aerosol, the aerosol-generating article including a planar frame and an aerosol-generating substrate,

[0006] the planar frame including:

[0007] a top surface, a bottom surface, and lateral sides;

[0008] an inlet provided on a lateral side,

[0009] An outlet provided on a lateral side opposite to the inlet;

[0010] A recess between the inlet and the outlet;

[0011] And an opening on the top surface;

[0012] Wherein the aerosol - generating substrate is disposed in the recess, and the aerosol - generating substrate is smaller than the opening.

[0013] This aerosol - generating article has the following advantages:

[0014] ● The article allows for improved ease of use because the user can easily insert the aerosol - generating substrate through the opening into the recess in the frame. The opening and recess of the planar frame provide an easy - to - use user interface.

[0015] ● The article can be personalized. During each user experience, the user can select a specific aerosol - generating substrate or other medium, or a combination of aerosol - generating substrates or other media, and decide which to use with the frame, or decide on the position of different aerosol - generating substrates or other media within the frame. Different positions of the aerosol - generating substrate (e.g., one position is closer to the air outlet than another) can provide different user experiences. The user can choose, for example, different aerosol - generating segments or different flavor segments. The personalization of the article does not adversely affect characteristics such as the airflow through the article.

[0016] ● The planar - frame shape of the article can be easily manufactured and can have a low manufacturing cost compared to bar - shaped articles. Bar - shaped articles can be made of several rods wrapped together, each rod having a specific function (such as cooling, filtering), and each rod requires a dedicated manufacturing process.

[0017] ● The planar frame is compact and versatile, thus improving the user experience.

[0018] As used herein, "planar" refers to a feature that is generally formed in a single Euclidean plane and does not wrap around or otherwise conform to fit a curved or other non - planar shape. A planar surface extends in two dimensions in a single Euclidean plane. A planar object extends in two dimensions in a single Euclidean plane to a substantially greater extent than it extends in a third dimension perpendicular to that plane. More specifically, a planar object extends in a first dimension and a second dimension perpendicular to the first dimension by at least two times, five times, or ten times more than it extends in a third dimension perpendicular to the first and second dimensions. Advantageously, the planar components of the heating assembly can be easily handled during manufacturing and provide a robust construction.

[0019] As used herein, an "aerosol generating device" refers to a device that interacts with an aerosol generating substrate to generate an aerosol.

[0020] As used herein, an "aerosol generating 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 generating substrate. The aerosol generating substrate is typically part of an aerosol generating article.

[0021] As used herein, the term "aerosol generating article" refers to an article that includes an aerosol generating substrate capable of releasing volatile compounds that can form an aerosol. For example, an aerosol generating article can be an article that generates an aerosol that can be directly inhaled by a user by sucking on a mouthpiece at the proximal or mouth end of the aerosol generating article, aerosol generating device, or aerosol generating system. The aerosol generating article can be disposable.

[0022] As used herein, an "aerosol generating system" refers to a combination of an aerosol generating device and an aerosol generating article. In an aerosol generating system, the aerosol generating article and the aerosol generating device cooperate to generate an aerosol.

[0023] As used herein, "proximal" refers to the user end or mouth end of an aerosol generating device, aerosol generating article, or aerosol generating system. The proximal end of a component of an aerosol generating device, aerosol generating article, or aerosol generating system is the end of the component that is closest to the user end or mouth end of the aerosol generating device, aerosol generating article, or aerosol generating system. As used herein, "distal" refers to the end opposite the proximal end.

[0024] As used herein, "end" and "side" are used interchangeably to refer to the ends of features such as an aerosol generating device, heating assembly, heating element, or aerosol generating article. Preferably, the features described herein have two opposite ends and at least one side extending between the two opposite ends. Preferably, the features described herein have a length extending in a longitudinal direction between the opposite ends and a width extending in a transverse direction between two opposite sides.

[0025] As used herein, "top surface" and "bottom surface" are relative terms used to refer to opposite surfaces of features such as an aerosol generating device, heating assembly, heating element, aerosol generating article, or planar frame. The top surface can be located above the bottom surface during normal use of the feature, but it should be understood that alternative orientations of the feature during use are possible. The top surface can be an upper surface. The bottom surface can be a lower surface.

[0026] As used herein, "length" refers to the maximum dimension of a feature in the longitudinal direction of the feature.

[0027] As used herein, "width" refers to the maximum dimension of a feature in the lateral direction of the feature. The lateral direction is perpendicular to the longitudinal direction.

[0028] As used herein, "thickness" and "depth" refer to the maximum dimension of a feature in a direction perpendicular to both the longitudinal direction of the feature and the lateral direction of the feature. The terms "thickness" and "depth" may be used interchangeably herein.

[0029] As used herein, the term "aerosol former" may refer to any suitable known compound or mixture of compounds that promotes the formation of an aerosol in use. The aerosol may be a dense and stable aerosol. The aerosol may be substantially heat resistant to degradation at the operating temperature of the aerosol generating substrate or aerosol generating article. Suitable aerosol formers included in the aerosol generating substrate are known in the art and include, but are not limited to: polyols such as triethylene glycol, propylene glycol, 1,3 - butanediol and glycerol; esters of polyols such as glycerol mono-, di - or tri - acetate; and aliphatic esters of mono-, di - or poly - carboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate. Glycerol as an aerosol former may be particularly preferred. The aerosol former content described with respect to the first aerosol generating substrate and the second aerosol generating substrate may equally be regarded as the glycerol content.

[0030] As used herein, unless otherwise specified, the term "aerosol former content" may refer to the aerosol former content in percentage by dry weight. The aerosol former content of the first aerosol generating substrate is based on the weight of the first aerosol generating substrate, and the aerosol former content of the second aerosol generating substrate is based on the weight of the second aerosol generating substrate.

[0031] As used herein, the terms "upstream" and "downstream" may refer to the relative position of an element or a part of an element with respect to the direction in which air or aerosol is transported through the aerosol generating article during use.

[0032] As used herein, unless otherwise specified, the term "bulk density" may refer to the bulk density by dry weight. The bulk density of the aerosol generating substrate or segment may be calculated by measuring or otherwise determining the total dry weight of the aerosol generating substrate or segment and dividing it by the volume of the aerosol generating segment substrate or segment.

[0033] At least 50 wt% of the aerosol generating article may be paper or cardboard. At least 55 wt%, or at least 60 wt%, or at least 65 wt%, or at least 70 wt%, or at least 75 wt%, or at least 80 wt%, or at least 85 wt%, or at least 90 wt% of the aerosol generating article (excluding the aerosol forming substrate) may be paper or cardboard.

[0034] The aerosol - forming substrate can be disposed in a recess of the aerosol - generating article such that when the article is inserted into the device, at least one side of the aerosol - forming substrate is exposed between the inlet and the outlet. The aerosol - forming substrate can be disposed in the recess such that when the article is inserted into the device, at least one side of the aerosol - forming substrate is visible between the inlet and the outlet. The recess can be configured such that a user can directly insert the aerosol - forming substrate through an opening into the planar frame without the need to open a lid, covering, or top wall, or remove any other component that obscures the aerosol - forming substrate in the recess. The recess can be configured such that a user can directly remove the aerosol - forming substrate from the planar frame through the opening. The aerosol - generating article can be configured such that the opening remains open when the aerosol - generating article is inserted into the device. The aerosol - generating article can be configured such that the opening remains open until the aerosol - generating article is inserted into the device, at which point it can be partially or fully covered by the device.

[0035] The frame can include a planar base. The frame can include a peripheral wall. The base and the peripheral wall can define a recess.

[0036] The frame can be substantially flat. The frame can be substantially elongated. The frame can have at least two substantially parallel outer edges. The frame can have at least two pairs of substantially parallel outer edges. The frame can have the shape of a substantially parallelepiped. The frame can have a length, a width, and a depth. The length can be greater than each of the width and the depth. The frame can be elongated along the frame length. The frame can have a rectangular cross - section. The frame can have a rectangular lateral cross - section that is aligned with the frame width and the frame thickness. The longitudinal axis along the length of the frame can be perpendicular to the plane of the lateral cross - section.

[0037] The inlet and the outlet can be disposed at opposite ends of the length of the frame. The inlet can be disposed at the upstream end of the frame. The inlet can be disposed at the distal end of the frame. The outlet can be disposed at the downstream end of the frame. The outlet can be disposed at the proximal end of the frame. The inlet can be disposed at an end of the frame that is perpendicular to the length of the frame. The outlet can be disposed at an end of the frame that is perpendicular to the length of the frame. The frame can have a longitudinal axis. The longitudinal axis can be a central axis that is aligned with the length of the frame. The inlet can intersect the longitudinal axis. The inlet can be arranged such that the longitudinal axis intersects the center point of the inlet. The inlet can be offset from the longitudinal axis. The outlet can intersect the longitudinal axis. The outlet can be arranged such that the longitudinal axis intersects the center point of the outlet. The outlet can be offset from the longitudinal axis. The inlet can be offset from the outlet. Offsetting the inlet or the outlet (or both the inlet and the outlet) from each other has the advantage of increasing the air turbulence within the article, which improves the mixing of ambient air with the aerosol generated by the heated aerosol - forming substrate.

[0038] The ratio of the frame width to the frame thickness can be at least about 3:1. The ratio of the frame width to the frame thickness can be at most about 30:1. The ratio of the frame width to the frame thickness can be between about 3:1 and about 30:1. The ratio of the frame width to the frame thickness can be about 30:3. The ratio of the frame length to the frame width can be at least about 1:1. The ratio of the frame length to the frame width can be at most about 5:1. The ratio of the frame length to the frame width can be between about 1:1 and about 5:1. The ratio of the frame length to the frame width can be about 5:1.

[0039] The frame can have a thickness of at least about 1 millimeter. The frame can have a thickness of at most about 3 millimeters. The frame can have a thickness between about 1 millimeter and about 3 millimeters. The frame can have a width of at least about 10 millimeters. The frame can have a width of at most about 30 millimeters. The frame can have a width between about 10 millimeters and about 30 millimeters. The frame can have a length of at least about 30 millimeters. The frame can have a length of at most about 50 millimeters. The frame can have a length between about 30 millimeters and about 50 millimeters.

[0040] The peripheral wall can extend from the base in the thickness direction of the frame. The peripheral wall can be aligned along the outer edge of the base. The peripheral wall can be aligned along all sides and ends of the base. When the base is rectangular, the peripheral wall can be aligned along one or both ends of the base. When the base is rectangular, the peripheral wall can be aligned along one or both sides of the base. The peripheral wall can be located at the outer edge of the base. The peripheral wall can extend along the circumference of the base. The peripheral wall can extend along most of the circumference of the base. The peripheral wall can extend along all of the circumference of the base not occupied by the inlet or outlet. The peripheral wall can be provided on the same surface of the base as the aerosol-generating substrate.

[0041] The peripheral wall can comprise or consist of a cellulose material or a cellulose-based material. The peripheral wall can comprise or consist of a paper-based material. The cellulose material can be one or more of the following: paper, cellulose acetate. The peripheral wall can contain one or more of the following: porous or fibrous materials, cellulose acetate, synthetic fibers, polyester, bonded polyolefin, polyethylene, polyester, polyethylene terephthalate, polypropylene, biopolymers, biopolymer fibers, polyamides, nylon, nylon fibers, ceramics, ceramic fibers.

[0042] The peripheral wall may have a peripheral wall thickness in the depth direction. The peripheral wall thickness may be at least about 1 millimeter. The peripheral wall thickness may be at most about 3 millimeters. The peripheral wall thickness may be between about 1 millimeter and about 3 millimeters. The peripheral wall may have a length of at least about 30 millimeters. The peripheral wall may have a length of at most about 50 millimeters. The peripheral wall may have a length between about 30 millimeters and about 50 millimeters. The peripheral wall may have a width of at least about 10 millimeters. The peripheral wall may have a width of at most about 30 millimeters. The peripheral wall may have a width between about 10 millimeters and about 30 millimeters.

[0043] The inlet and outlet may be orifices provided in the peripheral wall. The peripheral wall may have an upstream portion in which the inlet is provided. The peripheral wall may have a downstream portion in which the outlet is provided. The upstream portion and the downstream portion may be substantially parallel to each other. The peripheral wall may have a first side portion and a second side portion that may be substantially parallel to each other.

[0044] The peripheral wall may have an internal shape that is substantially the same as one or more outer edges of the aerosol - generating substrate. The peripheral wall may have an internal shape that is larger than the outer edge of the aerosol - generating substrate. A gap may exist between the peripheral wall and the outer edge of the aerosol - generating substrate. A gap may exist between the peripheral wall and all of the outer edges of the aerosol - generating substrate. The peripheral wall may conform to the contour of one or more outer edges of the aerosol - generating substrate.

[0045] The peripheral wall may include a first section and a second section, and the first section and the second section may be separated from each other by the inlet and the outlet. The first section and the second section may each have a convex portion at their downstream ends. The convex portions may be arranged to face each other. The first section may be substantially L - shaped. The first section may extend completely along one lateral side of the frame and partially along the other lateral side of the frame. The second section may be substantially U - shaped. The second section may extend completely along one lateral side of the frame and partially along the two other lateral sides of the frame. The first section and the second section may be coplanar. The first section and the second section may be substantially parallel to each other. A recess may be defined between the first section and the second section.

[0046] The base may be planar. The base may be substantially rectangular. The base may be elongated. The base may be a layer of material. The base may include an impermeable material. The base may include a biodegradable material. The base may include a cellulose material or be composed of a cellulose material. The cellulose material may be one or more of the following: paper, cellulose acetate. The base may include a paper - based material or be composed of a paper - based material. The base may include paper or be composed of paper. The base may be a paper layer. The base may contain one or more of the following: paper, paper - based material, plastic, polyethylene, polyester, polyethylene terephthalate, or polypropylene.

[0047] The base may have a base thickness in the depth direction. The base thickness may be at least about 0.05 millimeters. The base thickness may be at most about 0.1 millimeters. The base thickness may be between about 0.05 millimeters and about 0.1 millimeters. The base may have a length of at least about 30 millimeters. The base may have a length of at most about 50 millimeters. The base may have a length between about 30 millimeters and about 50 millimeters. The base may have a width of at least about 10 millimeters. The base may have a width of at most about 30 millimeters. The base may have a width between about 10 millimeters and about 30 millimeters.

[0048] The peripheral wall may have a peripheral wall thickness in the depth direction. The base thickness may be substantially less than the peripheral wall thickness. The base may be fixedly attached to the peripheral wall. The base and the peripheral wall may be sealed. The base and the peripheral wall may be hermetically sealed.

[0049] The inlet may have a length of at least about 10 millimeters. The inlet may have a length of at most about 20 millimeters. The inlet may have a length between about 10 millimeters and about 20 millimeters. The inlet may have a width of at least about 10 millimeters. The inlet may have a width of at most about 20 millimeters. The inlet may have a width between about 10 millimeters and about 20 millimeters. The inlet may have a depth of at least about 3 millimeters. The inlet may have a depth of at most about 7 millimeters. The inlet may have a depth of about 5 millimeters. The inlet may have a length of 1 millimeter. The inlet may have a width of 1 millimeter.

[0050] The outlet may have a length of at least about 10 millimeters. The outlet may have a length of at most about 20 millimeters. The outlet may have a length between 10 millimeters and 20 millimeters. The outlet may have a width of at least about 10 millimeters. The outlet may have a width of at most about 20 millimeters. The outlet may have a width between about 10 millimeters and about 20 millimeters. The outlet may have a depth of at least about 3 millimeters. The outlet may have a depth of at most about 7 millimeters. The outlet may have a depth of about 5 millimeters. The outlet may have a length of 1 millimeter. The outlet may have a width of 1 millimeter.

[0051] The outlet may be an aerosol outlet. The outlet may be at the mouthpiece of the aerosol-generating article.

[0052] The outlet may be shaped to create a Venturi effect. By being shaped to create a Venturi effect, the outlet defines a section of the airflow path that narrows and then expands. This accelerates the airflow and then causes it to expand. This has the advantage of cooling the air leaving the article and improving nucleation and aerosol generation.

[0053] The opening may be arranged to allow the aerosol-forming substrate to be inserted into the frame in the depth direction of the frame.

[0054] The article may have an upper surface area, and the opening may occupy at least about 50% of the upper surface area, preferably at least about 70% of the upper surface area, more preferably at least about 80% of the upper surface area.

[0055] The opening may have a length of at least about 20 mm, preferably at least about 24 mm, more preferably at least about 26 mm. The opening may have a length of at most about 46 mm, preferably at most about 44 mm. The opening may have a length between about 20 mm and about 46 mm, preferably between about 25 mm and about 44 mm. The opening may have a width of at least about 4 mm, preferably at least about 6 mm. The opening may have a width of at most about 36 mm, preferably at most about 34 mm. The opening may have a width between about 4 mm and about 36 mm, preferably between about 6 mm and about 34 mm.

[0056] The opening may be substantially two-dimensional. The opening may have a negligible depth. The opening may be elongated in the longitudinal direction of the frame. The opening may be planar. The opening may be substantially rectangular. The opening may be defined by a peripheral wall. The opening may be defined by the outermost edge of the peripheral wall. The outermost edge may be the outermost edge in the depth direction of the peripheral wall. The peripheral wall may extend from the opening to the base. The opening may have a size that is at least 50% of the planar area of the base. The opening may have a size that is at least 60% of the planar area of the base. The opening may have a size that is at least 70% of the planar area of the base. The opening may have a size that is at least 80% of the planar area of the base.

[0057] The recess may have a length of at least about 20 mm, preferably at least about 24 mm, more preferably at least about 26 mm. The recess may have a length of at most about 46 mm, preferably at most about 44 mm. The recess may have a length between about 20 mm and about 46 mm, preferably between about 25 mm and about 44 mm. The recess may have a width of at least about 4 mm, preferably at least about 6 mm. The recess may have a width of at most about 36 mm, preferably at most about 34 mm. The recess may have a width between about 4 mm and about 36 mm, preferably between about 6 mm and about 34 mm. The recess may extend between the opening and the base. The recess may extend from the opening to the base. The recess may have a depth. The depth of the recess may be equal to the thickness of the peripheral wall. The recess depth may be at least about 1 mm. The recess depth may be at most about 3 mm. The recess depth may be between about 1 mm and about 3 mm.

[0058] The recess may be elongated. The recess may be planar. The recess may define a substantially rectangular longitudinal cross-section. The recess may define a substantially rectangular lateral cross-section. The recess may be defined by a peripheral wall.

[0059] The recess may extend above at least 50% of the area of the base. The recess may extend above at least 60% of the area of the base. The recess may extend above at least 70% of the area of the base. The recess may extend above at least 80% of the area of the base.

[0060] The inlet may have a cross-sectional area. The opening may have a cross-sectional area. The ratio of the inlet cross-sectional area to the opening cross-sectional area may be between about 4:1 and 1:15, preferably between about 1:1 and 1:10.

[0061] The outlet may have a cross-sectional area. The ratio of the outlet cross-sectional area to the opening cross-sectional area may be between about 4:1 and 1:15, preferably between about 1:1 and 1:10.

[0062] The base may be hermetically sealed to the peripheral wall.

[0063] The frame may comprise a biodegradable material. This has the advantage of reducing the cost of managing environmental pollution. The frame may comprise a cellulose material or be composed of a cellulose material. The frame may comprise a paper-based material. The cellulose material may be one or more of the following: paper, cellulose acetate.

[0064] The aerosol-generating substrate may comprise a polyol or a mixture thereof, such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerol. The aerosol-generating substrate may comprise a plant-based material, such as loose tobacco or herbal fibers.

[0065] Suitable types of materials for use in the aerosol-generating substrate are described below and include, for example, tobacco cut filler, homogenized tobacco materials such as cast leaves, aerosol-generating films, and gel compositions.

[0066] Preferably, the aerosol-generating substrate comprises a tobacco material. In certain preferred embodiments, the aerosol-generating substrate comprises shredded tobacco material. For example, as described in more detail below, the shredded tobacco material may be in the form of cut filler. Alternatively, the shredded tobacco material may be in the form of pieces of homogenized tobacco material. Suitable homogenized tobacco materials are described below. In the context of this specification, the term "cut filler" is used to describe a blend of shredded plant material, such as tobacco plant material, and particularly includes one or more of leaves, processed stems and ribs, and homogenized plant material. Cut filler may also include other post-cut filler tobacco or flavorings.

[0067] 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 clove. Most preferably, the plant material is tobacco. However, other plant materials can also be used, such as other plant materials capable of releasing substances that can subsequently form an aerosol when heat is applied.

[0068] Preferably, the shredded filler comprises tobacco plant material, and the tobacco plant material comprises a thin layer of one or more of flue-cured tobacco, sun-cured tobacco, oriental tobacco, and filler tobacco. The term "tobacco" can refer to any plant member of the genus Nicotiana.

[0069] In a preferred embodiment, the weight of the shredded filler is between 25 mg and 150 mg, preferably between 30 mg and 125 mg, more preferably between 40 mg and 100 mg. This amount of shredded filler generally allows for sufficient material to form an aerosol during early puffing.

[0070] Preferably, the shredded filler is soaked with an aerosol-forming agent. Soaking the shredded filler can be accomplished by spraying or by other suitable application methods. The aerosol-forming agent can be applied to the blend during the preparation of the shredded filler. For example, the aerosol-forming agent can be applied to the blend in a direct conditioning casing cylinder (DCCC). Conventional machines can be used to apply the aerosol-forming agent to the shredded filler. Suitable aerosol-forming agents are set forth above.

[0071] Preferably, the aerosol-forming agent in the shredded filler comprises one or more of glycerol and propylene glycol. The aerosol-forming agent can consist of glycerol or propylene glycol or a combination of glycerol and propylene glycol.

[0072] In other preferred embodiments, the aerosol - forming substrate comprises homogenized plant material, preferably homogenized tobacco material. As used herein, the term "homogenized plant material" encompasses any plant material formed by the coalescence of plant particles. For example, a sheet or web of homogenized tobacco material for use in an aerosol - forming substrate can be formed by coalescing particles of tobacco material obtained by crushing, grinding, or milling plant material and optionally one or more of tobacco leaves and tobacco stems. The homogenized plant material can be produced by casting, extrusion, papermaking processes, or any other suitable process known in the art. In some embodiments, the homogenized plant material can be in the form of one or more sheets. The homogenized plant material can be in the form of a plurality of pellets or microparticles. The homogenized plant material can be in the form of a plurality of strands, strips, or fragments. Strands of homogenized plant material can be formed from sheets of homogenized plant material, for example by cutting or shredding, or by other methods, such as by an extrusion method.

[0073] One or more sheets as described herein can each individually have a thickness between 100 microns and 600 microns, preferably between 150 microns and 300 microns, and most preferably between 200 microns and 250 microns. The individual thickness refers to the thickness of an individual sheet, while the combined thickness refers to the total thickness of all the sheets that make up the aerosol - forming substrate.

[0074] One or more sheets as described herein can be one or more of curled, folded, aggregated, and pleated.

[0075] One or more sheets of the homogenized plant material can be cut into strands as described above. In such embodiments, the aerosol - forming substrate comprises a plurality of strands of homogenized plant material. The strands can be used to form a rod. Generally, the width of these strands is about 5 mm, or about 4 mm, or about 3 mm, or about 2 mm or less. The length of the strands can be greater than about 5 mm, between about 5 mm and about 15 mm, between about 8 mm and about 12 mm, or about 12 mm. Preferably, the strands have lengths that are substantially the same as each other.

[0076] The homogenized plant material can comprise between 2.5 wt% and 95 wt%, or between 5 wt% and 90 wt%, or between 10 wt% and 80 wt%, or between 15 wt% and 70 wt%, or between 20 wt% and 60 wt%, or between 30 wt% and 50 wt% of plant particles by dry weight.

[0077] In some embodiments, the homogenized plant material is a homogenized tobacco material comprising tobacco particles. Sheets of the homogenized tobacco material for use in such embodiments may have a tobacco content of at least about 40 wt%, more preferably at least about 50 wt%, more preferably at least about 70 wt% and most preferably at least about 90 wt% on a dry weight basis.

[0078] The term "tobacco particles" can describe particles of any plant member of the genus Nicotiana. The term "tobacco particles" includes ground or shredded tobacco leaves, ground or shredded tobacco stalks, tobacco dust, tobacco fines and other particulate tobacco by-products formed during the handling, processing and transportation of tobacco. In preferred embodiments, the tobacco particles are substantially all derived from tobacco leaves. In contrast, isolated nicotine and nicotine salts are compounds extracted from tobacco but are not considered tobacco particles for the purposes of this disclosure and are not included in the percentage of particulate plant material.

[0079] The aerosol-forming substrate may contain nicotine. As used herein, the term "nicotine" is used to describe nicotine, nicotine base or nicotine salts. In embodiments in which the aerosol-forming substrate contains nicotine base or nicotine salts, the amounts of nicotine described herein are the amounts of free base nicotine or protonated nicotine, respectively.

[0080] The aerosol-forming substrate may contain nicotine in an amount between 0.5 wt% and 10 wt%, or between 1 wt% and 8 wt%, or between 2 wt% and 6 wt% on a dry weight basis.

[0081] The aerosol-forming substrate may be substantially free of tobacco.

[0082] Preferably, the aerosol-forming substrate is 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 also contain a cellulose-based reinforcing agent. The aerosol-forming film may also include water, preferably 30 wt% or less water.

[0083] The term "cellulose-based film-forming agent" is used to describe a cellulose polymer capable of forming a continuous film alone or in the presence of an auxiliary thickening agent.

[0084] Preferably, the cellulose-based film-forming agent is selected from hydroxypropyl methylcellulose (HPMC), methylcellulose (MC), ethylcellulose (EC), hydroxyethyl methylcellulose (HEMC), hydroxyethylcellulose (HEC), hydroxypropylcellulose (HPC) and combinations thereof. More preferably, the cellulose-based film-forming agent is selected from hydroxypropyl methylcellulose (HPMC), methylcellulose (MC), ethylcellulose (EC) and combinations thereof.

[0085] Preferably, the aerosol - forming film further comprises a cellulose - based reinforcing agent. Preferably, the cellulose - based reinforcing agent is selected from cellulose fibers, microcrystalline cellulose (MCC), cellulose powder, and combinations thereof.

[0086] The aerosol - forming film may have a cellulose - based reinforcing agent content of between 0.5 wt% and 40 wt% on a dry weight basis, or between 5 wt% and 30 wt% on a dry weight basis, or between 10 wt% and 25 wt% on a dry weight basis.

[0087] The aerosol - forming film may further comprise carboxymethyl cellulose, preferably sodium carboxymethyl cellulose.

[0088] The aerosol - forming film may have a carboxymethyl cellulose content of between 1 wt% and 15 wt% on a dry weight basis, or between 2 wt% and 12 wt% on a dry weight basis, or between 4 wt% and 10 wt% on a dry weight basis.

[0089] The aerosol - forming film preferably comprises nicotine.

[0090] In embodiments where the aerosol - forming film comprises nicotine base or a nicotine salt, the amounts of nicotine described herein are the amounts of free - base nicotine or protonated nicotine, respectively.

[0091] The aerosol - forming film may comprise natural nicotine or synthetic nicotine.

[0092] The aerosol - forming film may comprise one or more monovalent nicotine salts.

[0093] As used herein, the term "monovalent nicotine salt" is used to describe a nicotine salt of a monobasic acid.

[0094] Preferably, the aerosol - forming film comprises at least 0.5 wt% of nicotine on a dry weight basis. More preferably, the aerosol - forming film comprises at least 1 wt% of nicotine on a dry weight basis. Even more preferably, the aerosol - forming film comprises at least 2 wt% of nicotine on a dry weight basis. Additionally, or alternatively, the aerosol - forming film preferably comprises less than 10 wt% of nicotine on a dry weight basis. More preferably, the aerosol - forming film comprises less than 8 wt% of nicotine on a dry weight basis. Even more preferably, the aerosol - forming film comprises less than 6 wt% of nicotine on a dry weight basis.

[0095] For example, the aerosol - forming film may comprise nicotine in an amount between 0.5 wt% and 10 wt% on a dry weight basis, or between 1 wt% and 8 wt% on a dry weight basis, or between 2 wt% and 6 wt% on a dry weight basis.

[0096] The aerosol - forming film may be a substantially tobacco - free aerosol - forming film.

[0097] 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.

[0098] Preferably, the aerosol - forming film comprises an acid in an amount between 0.25 wt% and 3.5 wt% based on dry weight, or between 0.5 wt% and 3 wt%, or between 1 wt% and 2.5 wt%.

[0099] The aerosol - forming film may have a thickness of from about 0.1 mm to about 1 mm, more preferably from about 0.1 mm to about 0.75 mm, even more preferably from about 0.1 mm to about 0.5 mm. In a particularly preferred embodiment, a layer of the film - forming composition is formed with a thickness of from about 50 microns to 400 microns, more preferably from about 100 microns to 200 microns.

[0100] Optionally, the aerosol - forming film may be disposed on a suitable carrier element within the second aerosol - forming segment.

[0101] In an alternative embodiment, the second aerosol - forming matrix may comprise a gel composition that contains nicotine, at least one gelling agent and an aerosol - forming agent. The gel composition is preferably substantially free of tobacco.

[0102] The preferred weight ranges of nicotine in the gel composition are the same as those defined above for the aerosol - forming film.

[0103] The gel composition preferably comprises at least 50 wt% of an aerosol - forming agent based on dry weight, more preferably at least 60 wt%, even more preferably at least 70 wt%. The gel composition may comprise up to 80 wt% of an aerosol - forming agent. The aerosol - forming agent in the gel composition is preferably glycerol.

[0104] The gel composition preferably comprises at least one gelling agent. Preferably, the total amount of gelling agent comprised in the gel composition is in the range of from about 0.4 wt% to about 10 wt%, or from about 0.5 wt% to about 8 wt%, or from about 1 wt% to about 6 wt%, or from about 2 wt% to about 4 wt%, or from about 2 wt% to about 3 wt%.

[0105] The term "gelling agent" refers to a compound that, when added in an amount of about 0.3 wt% to a 50 wt% water / 50 wt% glycerol mixture, homogeneously forms a solid medium or a supporting matrix that results in a gel. Gelling agents include, but are not limited to, hydrogen - bond cross - linking gelling agents and ion - cross - linking gelling agents.

[0106] The term "hydrogen - bond cross - linking gelling agent" refers to a gelling agent that forms non - covalent cross - links or physical cross - links via hydrogen bonds.

[0107] The hydrogen bond cross-linked gelling agent may include one or more of galactomannan, gelatin, agarose, konjac gum or agar. The hydrogen bond cross-linked gelling agent may preferably include agar.

[0108] The term "ionic cross-linked gelling agent" refers to a gelling agent that forms non-covalent cross-linking bonds or physical cross-linking bonds via ionic bonds.

[0109] The ionic cross-linked gelling agent may include low acyl gellan gum, pectin, κ-carrageenan, ι-carrageenan or alginate. The ionic cross-linked gelling agent may preferably include low acyl gellan gum.

[0110] The gelling agent may include one or more biopolymers. The biopolymers may be formed from polysaccharides.

[0111] Biopolymers include, for example, gellan gum (natural, low acyl gellan gum, high acyl gellan gum, preferably low acyl gellan gum), xanthan gum, alginate (algic 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 two biopolymers of substantially equal weight. The composition may include three biopolymers of substantially equal weight.

[0112] The gel composition may further contain a thickener. The thickener combined with the hydrogen bond cross-linked gelling agent and the ionic cross-linked gelling agent unexpectedly appears to support the solid medium and maintain the gel composition, even when the gel composition contains a high level of glycerol.

[0113] The term "thickener" refers to a compound that increases the viscosity without causing gel formation and the mixture remains or retains fluid when homogeneously added to a mixture of 25 °C, 50 wt% water / 50 wt% glycerol in an amount of 0.3 wt%.

[0114] The gel composition preferably contains a thickener 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%.

[0115] The thickener may include one or more of xanthan gum, carboxymethyl cellulose, microcrystalline cellulose, methyl cellulose, gum arabic, guar gum, λ-carrageenan or starch. The thickener may preferably include xanthan gum.

[0116] The gel composition may further comprise divalent cations. Preferably, the divalent cations include calcium ions, such as calcium lactate in solution. For example, divalent cations (such as calcium ions) can contribute to the gel formation of a composition comprising a gelling agent such as an ionic crosslinking gelling agent. The ionic effect can contribute to gel formation. The divalent cations may be present in the gel composition in the range of about 0.1 wt% to about 1 wt% or about 0.5 wt%.

[0117] The gel composition may further comprise an acid. The acid may include 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).

[0118] The gel composition preferably includes some water. When the gel composition includes some water, the gel composition is more stable.

[0119] Preferably, the water included in the gel composition is about 8 wt% to about 32 wt%, or about 15 wt% to about 25 wt%, or about 18 wt% to about 22 wt%, or about 20 wt%.

[0120] Preferably, when using the gel composition, the second aerosol - generating substrate includes a porous medium carrying the gel composition. The advantage of a porous medium carrying the gel composition is that the gel composition is retained within the porous medium, and this can contribute to the manufacture, storage or transportation of the gel composition. It can contribute to maintaining the desired shape of the gel composition, especially during manufacture, transportation or use.

[0121] 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.

[0122] The porous medium can be any suitable porous material capable of holding or retaining the gel composition. Ideally, the porous medium may allow the gel composition to move therein. In certain embodiments, the porous medium includes natural materials, synthetic or semi - synthetic materials, or combinations thereof. In certain embodiments, the porous medium includes sheet materials, foams or fibers, such as loose fibers; or combinations thereof. In certain embodiments, the porous medium includes woven, non - woven or extruded materials, or combinations thereof. Preferably, the porous medium includes cotton, paper, viscose fiber, PLA or cellulose acetate, or combinations thereof. Preferably, the porous medium includes sheet materials, such as cotton or cellulose acetate. In a particularly preferred embodiment, the porous medium includes a sheet made of cotton fibers. The porous medium can be crimped or shredded. The porous medium can be in the form of a sheet, thread or tubular element.

[0123] The aerosol - generating substrate can be flat. The aerosol - generating substrate can be planar. This has the following advantages: allowing the aerosol - generating substrate to be effectively heated by the heating element and improving the yield of the aerosol generated from the aerosol - generating substrate. By having a large surface - area - to - volume ratio and by having a thickness that is reduced compared to its length and width, the heating element can be positioned such that all of the aerosol - generating substrate is within a specified distance from the heating element. This has the advantages of providing an improved user experience and reducing the waste of aerosol - generating substrate during use.

[0124] The aerosol - generating substrate can be substantially aligned with a planar frame. The plane in which the aerosol - generating substrate extends can be substantially aligned or substantially parallel to the plane in which the planar frame extends.

[0125] The aerosol - generating substrate can have a thickness less than the thickness of the frame. The aerosol - generating substrate can be disposed on an adhesive. The combined thickness of the adhesive and the aerosol - generating substrate can be less than the thickness of the frame. The aerosol - generating substrate can have a thickness less than the thickness of the peripheral wall. The aerosol - generating substrate can be disposed on an adhesive, and the combined thickness of the adhesive and the aerosol - generating substrate can be less than the thickness of the peripheral wall. The aerosol - generating substrate can have a thickness such that when the aerosol - generating substrate is disposed in a recess, there is a gap between the upper surface of the aerosol - generating substrate and the upper surface of the frame. When the aerosol - generating substrate is disposed in a recess, there can be a gap between the upper surface of the aerosol - generating substrate and the upper surface of the peripheral wall.

[0126] The aerosol - generating substrate can have a thickness of at least about 0.1 mm. The aerosol - generating substrate can have a thickness of at most about 5 mm. The aerosol - generating substrate can have a thickness between about 0.1 mm and about 5 mm. The aerosol - generating substrate can have a width of at least about 10 mm. The aerosol - generating substrate can have a width of at most about 20 mm. The aerosol - generating substrate can have a width between about 10 mm and about 20 mm. The aerosol - generating substrate can have a length of at least about 10 mm. The aerosol - generating substrate can have a length of at most about 20 mm. The aerosol - generating substrate can have a length between about 10 mm and about 20 mm.

[0127] The aerosol - generating substrate can have a top - surface area. The top surface of the aerosol - generating substrate can be the surface of the aerosol - generating substrate that faces away from the base. The opening can have a cross - sectional area. The substrate top - surface area can be less than the opening cross - sectional area. The opening can have a cross - sectional area. The ratio of the substrate top - surface area to the opening cross - sectional area can be at least about 1:2, preferably at least about 1:1.5, more preferably at least about 1:1.2. The substrate top - surface area can be at least about 50% of the opening cross - sectional area, preferably at least about 70% of the opening cross - sectional area, more preferably at least about 80% of the opening cross - sectional area.

[0128] An aerosol-generating article may include an adhesive configured to attach an aerosol-generating substrate to a frame. The adhesive may include two or more adhesive regions. The adhesive may be polyvinyl acetate.

[0129] The aerosol-generating substrate may include a plurality of aerosol-generating segments. Two or more of the aerosol-generating segments may have the same shape, size, color, or texture as each other (or more than one of these parameters). Two or more of the aerosol-generating segments may have the same top surface area as each other. This has the advantage of allowing a user the flexibility to select and position the aerosol-generating segments. Two or more of the aerosol-generating segments may have the same bottom surface area as each other. The bottom surface area may be closer to the base of the frame in use than the top surface area.

[0130] Two or more of the aerosol-generating segments may have different shapes, sizes, colors, or textures as each other (or more than one of these parameters). This has the advantage of allowing a user to identify the contents of a segment by the shape, size, color, or texture of the segment. One or more segments containing nicotine may have a different shape, size, color, or texture from one or more segments containing less nicotine. One or more segments containing nicotine may have a different shape, size, color, or texture from one or more segments configured to provide a flavorant such as menthol to the user.

[0131] The aerosol-generating substrate may include a first aerosol-generating segment. The first aerosol-generating segment may include a first aerosol-generating substrate. The aerosol-generating substrate may include a second aerosol-generating segment. The second aerosol-generating segment may include a second aerosol-generating substrate. The first aerosol-generating substrate may have either or both of a lower aerosol-forming agent content and a lower bulk density compared to the second aerosol-generating substrate. At least a portion of the second aerosol-generating segment may be located at a position upstream of at least a portion of the first aerosol-generating segment.

[0132] The first aerosol-generating substrate and the second aerosol-generating substrate may include the same one or more aerosol-forming agents as each other, or different aerosol-forming agents may be used.

[0133] The first aerosol-generating segment and the second aerosol-generating segment may respectively include or be constituted by the first aerosol-generating substrate and the second aerosol-generating substrate. The first aerosol-generating substrate and the second aerosol-generating substrate may include non-aerosol-generating materials as well as aerosol-generating materials.

[0134] Optionally, on a dry weight basis, the aerosol former content of the first aerosol - forming substrate is between 10% and 30% by weight, preferably between 10% and 25% by weight, more preferably between 10% and 20% by weight. Optionally, on a dry weight basis, the aerosol former content of the second aerosol - forming substrate is between 40% and 80% by weight, preferably between 45% and 75% by weight, more preferably between 50% and 70% by weight.

[0135] Optionally, the first aerosol - forming substrate has a bulk density between 100 mg / cm³ and 400 mg / cm³, preferably between 150 mg / cm³ and 350 mg / cm³. Optionally, the second aerosol - forming substrate has a bulk density between 500 mg / cm³ and 1000 mg / cm³, preferably between 550 mg / cm³ and 900 mg / cm³. Optionally, the bulk density of the second aerosol - forming substrate is at least 1.1 times, 1.2 times, 1.5 times, 2 times or 2.5 times the bulk density of the first aerosol - forming substrate.

[0136] Optionally, the first aerosol - forming substrate has both a lower aerosol former content and a lower bulk density compared to the second aerosol - forming substrate.

[0137] Optionally, on a weight - by - weight basis and on a dry weight basis, the aerosol former content of the second aerosol - forming substrate is at least 2.5 times the aerosol former content of the first aerosol - forming substrate; and the bulk density of the second aerosol - forming substrate is at least 2.5 times the bulk density of the first aerosol - forming substrate.

[0138] Optionally, the aerosol former content of the first aerosol - forming substrate does not exceed 20% by weight on a dry weight basis, and the aerosol former content of the second aerosol - forming substrate is at least 50% by weight on a dry weight basis; and the first aerosol - forming substrate has a bulk density of less than 300 mg / cm³, and the second aerosol - forming substrate has a bulk density of at least 600 mg / cm³.

[0139] Optionally, at least a portion of the second aerosol - forming segment is upstream of at least a portion of the first aerosol - forming segment. Optionally, the second aerosol - forming segment is upstream of the first aerosol - forming segment. Optionally, the entire second aerosol - forming segment is upstream of the entire first aerosol - forming segment.

[0140] Optionally, the second aerosol - generating segment is spaced apart from the first aerosol - generating segment (e.g., upstream of the first aerosol - generating segment) by at least 0.5 mm, 1 mm or 2 mm. Optionally, the second aerosol - generating segment is spaced apart from the first aerosol - generating segment (e.g., upstream of the first aerosol - generating segment) by no more than 10 mm, 5 mm or 2 mm. Optionally, the second aerosol - generating segment is spaced apart from the first aerosol - generating segment (e.g., upstream of the first aerosol - generating segment) between 0.5 and 5 mm, preferably between 0.5 and 2 mm.

[0141] The first aerosol - generating segment may have a first length, a first width and a first thickness. The first thickness may be no more than 0.5 times the first length, preferably no more than 0.2 times, more preferably no more than 0.1 times. The first thickness may be no more than 0.5 times the first width, preferably no more than 0.2 times, more preferably no more than 0.1 times.

[0142] The second aerosol - generating segment may have a second length, a second width and a second thickness. The second thickness may be no more than 0.5 times the second length, preferably no more than 0.2 times, more preferably no more than 0.1 times. The second thickness may be no more than 0.5 times the second width, preferably no more than 0.2 times, more preferably no more than 0.1 times.

[0143] Optionally, one or both of the first aerosol - generating segment and the second aerosol - generating segment are prismatic in shape, e.g., cuboid or straight - cylindrical in shape. Optionally, the first aerosol - generating segment and the second aerosol - generating segment are the same in shape.

[0144] Optionally, one or both of the first aerosol - generating segment and the second aerosol - generating segment have a thickness of at least 0.05 mm, 0.1 mm or 0.2 mm. Optionally, one or both of the first aerosol - generating segment and the second aerosol - generating segment have a thickness of no more than 5 mm, 4 mm or 3 mm. Optionally, one or both of the first aerosol - generating segment and the second aerosol - generating segment have a thickness between 0.1 and 5 mm, preferably between 0.2 and 4 mm. Advantageously, such thicknesses provide a good compromise between the segment being thick enough to accommodate a reasonable amount of aerosol - generating substrate, but thin enough to allow the substrate furthest from the heater to be heated to a high enough temperature to generate aerosol without a significant risk of burning the substrate closest to the heater.

[0145] Optionally, one or both of the first aerosol - generating segment and the second aerosol - generating segment have a width of at least 5 or 10 millimeters. Optionally, one or both of the first aerosol - generating segment and the second aerosol - generating segment have a width of no more than 30 or 20 millimeters. Optionally, one or both of the first aerosol - generating segment and the second aerosol - generating segment have a width between 10 and 20 millimeters.

[0146] Optionally, one or both of the first aerosol - generating segment and the second aerosol - generating segment have a length of at least 5 or 10 millimeters. Optionally, one or both of the first aerosol - generating segment and the second aerosol - generating segment have a length of no more than 30 or 20 millimeters. Optionally, one or both of the first aerosol - generating segment and the second aerosol - generating segment have a length between 10 and 20 millimeters.

[0147] Advantageously, such widths and lengths can be particularly suitable for inserting one or more segments into a frame via an opening. Such widths and lengths allow a user to easily position one or both of the aerosol - generating segments within a recess, while being large enough to effectively generate a suitable amount of aerosol. Advantageously, such widths and lengths can also fit comfortably within an article that has a size that allows a user to comfortably hold it between their fingers, while still providing a sufficient amount of substrate to generate enough aerosol to satisfy the user during use.

[0148] The aerosol - generating article can be configured to be removably connected to an aerosol - generating device. The size or shape (or both the size and shape) of the aerosol - generating article can be set to be removably connected to the aerosol - generating device.

[0149] The aerosol - generating article can be disposed within an aerosol - generating system. The aerosol - generating system can include an aerosol - generating device. The aerosol - generating device can have a heating element configured to heat an aerosol - generating substrate to form an aerosol. The aerosol - generating device can have a device housing that defines a cavity. The aerosol - generating article can be disposed within the cavity of the device housing. The aerosol - generating article can be disposed within the cavity of the device housing to define an air - flow passage between the device housing and the frame of the article. The air - flow passage can extend from an inlet to an outlet.

[0150] The heating element can be substantially planar. The heating element can be substantially aligned with the aerosol - generating substrate. The plane of the heating element can be substantially aligned or substantially parallel to the plane of the aerosol - generating substrate.

[0151] An aerosol generating system may include a plurality of heating elements. The aerosol generating system may include a plurality of heating elements corresponding to the number of aerosol generating matrix segments of the aerosol generating article. This has the advantage of allowing the aerosol generating segments to undergo the same or different temperature profiles during use. The aerosol generating system may be configured to heat the aerosol generating matrix to a temperature of up to about 250 degrees Celsius during use.

[0152] The aerosol generating article may be configured to be inserted fully or partially into the aerosol generating device. The aerosol generating article may be configured to be inserted fully or partially into the aerosol generating device housing cavity. The aerosol generating article may be configured such that the opening of the frame is fully or partially enclosed by the wall of the device housing cavity. The aerosol generating article may be configured such that when the aerosol generating article is inserted into the device, the frame contacts the wall of the device housing cavity. The aerosol generating article may be configured such that when the aerosol generating article is inserted into the aerosol generating device, the peripheral wall contacts the wall of the device housing cavity. The aerosol generating article may be configured such that when the article is inserted into the aerosol generating device, the peripheral wall extends from the wall of the device housing cavity to the planar base of the frame. The aerosol generating article may be configured such that when the article is inserted into the device, the peripheral wall forms a seal with the wall of the device housing cavity. The aerosol generating article may be configured such that when the article is inserted into the aerosol generating device, the aerosol generating matrix is encapsulated between the wall of the device housing cavity, the peripheral wall of the frame, and the planar base of the frame. The aerosol generating article may be configured such that when the article is inserted into the aerosol generating device, an air flow path is defined between the device and the aerosol generating article. The aerosol generating article may be configured such that when the aerosol generating article is inserted into the aerosol generating device, an air flow path is defined between the device and the planar base. The aerosol generating article may be configured such that when the aerosol generating article is inserted into the aerosol generating device, air can pass through the inlet, towards the aerosol generating matrix within the recess and above the aerosol generating matrix, and exit through the outlet. When the air flows above the aerosol generating matrix, the air may be between the wall of the device cavity and the base of the frame of the aerosol generating article.

[0153] The present invention is defined in the claims. However, 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.

[0154] Example Ex1. An aerosol generating article for use with an aerosol generating device to form an inhalable aerosol, the aerosol generating article including a planar frame and an aerosol generating matrix,

[0155] The planar frame includes:

[0156] a top surface, a bottom surface, and lateral sides;

[0157] An inlet provided on a lateral side,

[0158] An outlet provided on a lateral side opposite to the inlet;

[0159] A recess between the inlet and the outlet;

[0160] And an opening on the top surface;

[0161] Wherein the aerosol - generating substrate is disposed in the recess, and the aerosol - generating substrate is smaller than the opening.

[0162] Example Ex2. The aerosol - generating article according to Example Ex1, wherein the frame comprises a planar base and a peripheral wall, and the base and the peripheral wall define the recess.

[0163] Example Ex3. The aerosol - generating article according to Example Ex2, wherein the inlet and the outlet are orifices provided in the peripheral wall.

[0164] Example Ex4. The aerosol - generating article according to Example Ex2 or Example Ex3, wherein the peripheral wall has an upstream portion where the inlet is provided, a downstream portion where the outlet is provided, and the upstream portion and the downstream portion are substantially parallel to each other.

[0165] Example Ex5. The aerosol - generating article according to any one of Examples Ex2 to Ex4, wherein the peripheral wall has a first side portion and a second side portion that are substantially parallel to each other.

[0166] Example Ex6. The aerosol - generating article according to any one of Examples Ex1 to Ex5, wherein the frame has a substantially parallelepiped shape.

[0167] Example Ex7. The aerosol - generating article according to any one of Examples Ex1 to Ex6, wherein the frame extends along a frame length, and the inlet and the outlet are provided at opposite ends of the frame length.

[0168] Example Ex8. The aerosol - generating article according to any one of Examples Ex1 to Ex7, wherein the frame has a length, a width, and a depth, the length is greater than each of the width and the depth, and the inlet and the outlet are provided at opposite ends of the frame length.

[0169] Example Ex9. The aerosol - generating article according to any one of Examples Ex1 to Ex8, wherein the ratio of the frame width to the frame thickness is between about 3:1 and 30:1.

[0170] Example Ex10. An aerosol-generating article according to any one of Examples Ex1 to Ex9, wherein the ratio of the frame length to the frame width is between about 1:1 and 5:1.

[0171] Example Ex11. An aerosol-generating article according to any one of Examples Ex1 to Ex10, wherein the frame has a thickness between about 1 mm and 3 mm.

[0172] Example Ex12. An aerosol-generating article according to any one of Examples Ex1 to Ex11, wherein the frame has a width between about 10 mm and 30 mm.

[0173] Example Ex13. An aerosol-generating article according to any one of Examples Ex1 to Ex12, wherein the frame has a length between about 30 mm and 50 mm.

[0174] Example Ex14. An aerosol-generating article according to any one of Examples Ex1 to Ex13, comprising an adhesive configured to attach the aerosol-generating substrate to the frame.

[0175] Example Ex15. An aerosol-generating article according to any one of Examples Ex2 to Ex14, wherein the base has a base thickness in the depth direction, the peripheral wall has a peripheral wall thickness in the depth direction, and the base thickness is substantially less than the peripheral wall thickness.

[0176] Example Ex16. An aerosol-generating article according to any one of Examples 1 to 15, wherein the inlet has a length between about 10 mm and 20 mm.

[0177] Example Ex17. An aerosol-generating article according to any one of Examples 1 to 16, wherein the inlet has a width between about 10 mm and 20 mm.

[0178] Example Ex18. An aerosol-generating article according to any one of Examples 1 to 17, wherein the inlet has a depth of about 5 mm.

[0179] Example Ex19. An aerosol-generating article according to any one of Examples 1 to 18, wherein the outlet has a length between about 10 mm and 20 mm.

[0180] Example Ex20. An aerosol-generating article according to any one of Examples 1 to 19, wherein the outlet has a width between about 10 mm and 20 mm.

[0181] Example Ex21. An aerosol-generating article according to any one of Examples 1 to 20, wherein the outlet has a depth of about 5 mm.

[0182] Example Ex22. An aerosol-generating article according to any one of Examples Ex1 to Ex21, wherein the opening has a length of at least about 20 millimeters.

[0183] Example Ex23. An aerosol-generating article according to any one of Examples Ex1 to Ex22, wherein the opening has a width of at least about 4 millimeters.

[0184] Example Ex24. An aerosol-generating article according to any one of Examples Ex1 to Ex23, wherein the recess has a depth between about 1 millimeter and about 3 millimeters.

[0185] Example Ex25. An aerosol-generating article according to any one of Examples Ex1 to Ex24, wherein the inlet has a cross-sectional area, the opening has a cross-sectional area, and the ratio of the inlet cross-sectional area to the opening cross-sectional area is between about 1:1 and 1:10.

[0186] Example Ex26. An aerosol-generating article according to any one of Examples Ex1 to Ex25, wherein the outlet has a cross-sectional area, the opening has a cross-sectional area, and the ratio of the outlet cross-sectional area to the opening cross-sectional area is between about 1:1 and 1:10.

[0187] Example Ex27. An aerosol-generating article according to any one of Examples Ex2 to Ex26, wherein the base is hermetically sealed to the peripheral wall.

[0188] Example Ex28. An aerosol-generating article according to any one of Examples Ex1 to Ex27, wherein the frame comprises a biodegradable material.

[0189] Example Ex29. An aerosol-generating article according to any one of Examples Ex1 to Ex28, wherein the frame comprises a cellulose material.

[0190] Example Ex30. The aerosol-generating article according to Example Ex29, wherein the cellulose material is one or more of the following: paper, cellulose acetate.

[0191] Example Ex31. An aerosol-generating article according to any one of Examples Ex1 to Ex30, wherein the aerosol-generating substrate is planar.

[0192] Example Ex32. An aerosol-generating article according to any one of Examples Ex1 to Ex31, wherein the aerosol-generating substrate is configured to generate an aerosol when heated to a temperature of about 250 degrees Celsius.

[0193] Example Ex33. An aerosol-generating article according to any one of Examples Ex1 to Ex32, wherein the aerosol-generating substrate has a thickness less than the thickness of the frame.

[0194] Example Ex34. An aerosol-generating article according to any one of Examples Ex2 to Ex33, wherein the aerosol-generating substrate has a thickness less than the thickness of the peripheral wall.

[0195] Example Ex35. An aerosol-generating article according to any one of Examples Ex1 to Ex34, wherein the aerosol-generating substrate has a thickness between about 0.1 mm and 5 mm.

[0196] Example Ex36. An aerosol-generating article according to any one of Examples Ex1 to Ex35, wherein the aerosol-generating substrate has a width between about 10 mm and 20 mm.

[0197] Example Ex37. An aerosol-generating article according to any one of Examples Ex1 to Ex38, wherein the aerosol-generating substrate has a length between about 10 mm and 20 mm.

[0198] Example Ex38. An aerosol-generating article according to any one of Examples Ex1 to Ex37, wherein the aerosol-generating substrate has a top surface area, the opening has a cross-sectional area, and the substrate top surface area is less than the opening cross-sectional area.

[0199] Example Ex39. An aerosol-generating article according to any one of Examples Ex1 to Ex38, wherein the aerosol-generating substrate has a top surface area, the opening has a cross-sectional area, and the ratio of the substrate top surface area to the opening cross-sectional area is at least about 1:2.

[0200] Example Ex40. An aerosol-generating article according to any one of Examples Ex1 to Ex39, wherein the aerosol-generating substrate comprises a first aerosol-generating segment and a second aerosol-generating segment, the first aerosol-generating segment comprises a first aerosol-generating substrate, and the second aerosol-generating segment comprises a second aerosol-generating substrate.

[0201] Example Ex41. The aerosol-generating article according to Example Ex40, wherein the first aerosol-generating substrate has one or both of a lower aerosol-forming agent content and a lower bulk density compared to the second aerosol-generating substrate.

[0202] Example Ex42. The aerosol-generating article according to Example Ex40 or Example Ex41, wherein at least a portion of the second aerosol-generating segment is located at a position upstream of at least a portion of the first aerosol-generating segment.

[0203] Example Ex43. An aerosol-generating system comprising:

[0204] An apparatus, the apparatus having a heating element configured to heat an aerosol - forming substrate to form an aerosol, and an apparatus housing defining a cavity; and

[0205] An aerosol - generating article according to any one of Examples Ex1 to Ex42; and

[0206] wherein the aerosol - generating article is disposed in the apparatus - housing cavity to define a flow path between the apparatus housing and a frame of the article, the flow path extending from the inlet to the outlet. Description of the Drawings

[0207] Several examples will now be further described with reference to the drawings, in which:

[0208] Figure 1 A schematic view of an aerosol - generating article according to the present disclosure is shown;

[0209] Figure 2 Is shown Figure 1 A schematic exploded - view illustration of the aerosol - generating article of

[0210] Figure 3 A schematic view in plan view of an aerosol - generating article according to the present disclosure is shown;

[0211] Figure 4 A cross - sectional schematic view of an aerosol - generating system according to the present disclosure is shown; and

[0212] Figure 5 A cross - sectional schematic view of an aerosol - generating article having marked dimensions according to the present disclosure is shown. Detailed Description

[0213] Figure 1 An aerosol - generating article 1 according to the present disclosure is shown. The aerosol - generating article 1 is for use with an aerosol - generating apparatus to form an inhalable aerosol. The aerosol - generating article 1 is a generally flat planar article having a rectangular cross - sectional shape.

[0214] The aerosol - generating article 1 includes a planar frame 4 and aerosol - forming substrates 5, 6. The aerosol - forming substrates 5, 6 are in two segments. The aerosol - forming substrates 5, 6 include: a first aerosol - forming segment including a first aerosol - forming substrate 5; and a second aerosol - forming segment including a second aerosol - forming substrate 6. The first aerosol - forming substrate 5 has one or both of a lower aerosol - forming agent content and a lower bulk density compared to the second aerosol - forming substrate 6.

[0215] The planar frame 4 includes a top surface 401, a bottom surface 407, and lateral sides 403, 404, 405, 406. The frame 4 includes an inlet 43 provided on the lateral side 406. The frame 4 includes an outlet 44 provided on the lateral side 405 opposite the inlet 43. The frame 4 includes a recess 45 between the inlet 43 and the outlet 44. The frame 4 includes an opening 46 in the top surface 401. The aerosol-generating substrates 5, 6 are disposed in the recess 45. The aerosol-generating substrates 5, 6 are smaller than the opening 46 and the recess 45.

[0216] The frame 4 includes a planar base 2 and peripheral walls 41, 42. The base 2 and the peripheral walls 41, 42 define the recess 45. The frame 4 includes a cellulose material. The frame 4 includes a biodegradable material. The frame 4 includes two adhesive regions 21 on the base 2 to which two aerosol-generating segments 5, 6 are fixed. As Figure 4 best seen, the bottom surfaces 51, 61 of the aerosol-generating segments are fixed to the base 2 via an adhesive.

[0217] The inlet 43 and the outlet 44 are orifices provided in the peripheral walls 41, 42. The peripheral walls 41, 42 include a first section 41 and a second section 42 separated from each other by the inlet 43 and the outlet 44. The first section 41 and the second section 42 each have a convex portion at their downstream ends, the convex portions facing each other. The first section 41 is substantially L-shaped. The first section 41 extends entirely along one lateral side 403 of the frame 4 and partially along the other lateral side 405 of the frame. The second section is substantially U-shaped. The second section 42 extends entirely along one lateral side 404 of the frame 4 and partially along the two other lateral sides 405, 406 of the frame. The first section 41 and the second section 42 are coplanar. The first section 41 and the second section 42 are substantially parallel to each other. The recess 45 is defined between the first section 41 and the second section 42.

[0218] The aerosol-generating substrates 5, 6 are planar. The aerosol-generating substrates 5, 6 have thicknesses 583, 683. The peripheral walls 41, 42 have thicknesses 413, 423. The aerosol-generating substrate thicknesses 583, 683 are less than the peripheral wall thicknesses 413, 423. The aerosol-generating substrates 5, 6 have top surfaces 52, 62 that have a top surface area. The opening 46 has a cross-sectional area. The substrate top surface area is less than the opening cross-sectional area. The ratio of the substrate top surface area to the opening cross-sectional area is at least about 1:2. As Figure 5As depicted, the frame 4 has a frame length 481 along the longitudinal axis 10. The frame 4 extends along the frame length 481. The inlet 43 and the outlet 44 are provided at opposite ends of the frame length 481. The frame 4 has a frame width 482. The frame 4 has a frame thickness 483. The ratio of the frame width 482 to the frame thickness 483 is between about 3:1 and 30:1. The ratio of the frame length 481 to the frame width 482 is between about 1:1 and 5:1.

[0219] Figure 4 An aerosol - generating system 100 is shown. The aerosol - generating system includes an aerosol - generating device 9. The aerosol - generating device 9 includes a device cavity into which an aerosol - generating article 1 is inserted, an inner wall 91, an air inlet 93, and a heating element 92.

[0220] As Figure 4 As best seen, when the aerosol - generating article 1 is inserted into the aerosol - generating device 9, the opening 46 is closed by the inner wall 91 of the device cavity. In this assembled state, the aerosol - generating matrices 5, 6 are close to the heating element 92 of the aerosol - generating device.

[0221] In use, when the user sucks on the aerosol outlet 44, an air flow 7 is drawn in, through the air inlet 93, through the air inlet 43 of the aerosol - generating article, above the heated aerosol - generating matrices 5, 6 where the aerosol is generated, and is delivered as an air flow containing the aerosol 8 to the outlet 44.

[0222] For the purposes of this specification and the appended claims, unless otherwise indicated, all numbers expressing quantities, amounts, percentages, etc. are to be understood as being modified in all instances by the term "about". Moreover, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therebetween, whether or not specifically enumerated herein. Thus, in this context, the number A is understood as A ± 10%A. In this context, the number A can be regarded as including values within the normal standard error for the measurement of the property modified by the number A. In some cases as used in the appended claims, the number A may deviate from the percentage recited above, so long as the amount by which A deviates does not significantly affect the basic and novel features of the claimed invention. Moreover, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therebetween, whether or not specifically enumerated herein.

Claims

1. An aerosol - generating article for use with an aerosol - generating device to form an inhalable aerosol, the aerosol - generating article comprising a planar frame and an aerosol - generating substrate, The planar frame comprises: a top surface, a bottom surface, and lateral sides; an inlet provided on a lateral side; an outlet provided on a lateral side opposite the inlet; a recess between the inlet and the outlet; and an opening on the top surface; wherein the aerosol - generating substrate is disposed in the recess and the aerosol - generating substrate is smaller than the opening.

2. The aerosol - generating article according to claim 1, wherein the frame comprises a planar base and a peripheral wall, and the base and the peripheral wall define the recess.

3. The aerosol - generating article according to claim 2, wherein the inlet and the outlet are orifices provided in the peripheral wall.

4. The aerosol - generating article according to any one of the preceding claims, wherein the frame extends along a frame length and the inlet and the outlet are provided at opposite ends of the frame length.

5. The aerosol - generating article according to any one of the preceding claims, wherein the ratio of the frame width to the frame thickness is between about 3:1 and 30:

1.

6. The aerosol - generating article according to any one of the preceding claims, wherein the ratio of the frame length to the frame width is between about 1:1 and 5:

1.

7. The aerosol - generating article according to any one of the preceding claims, wherein the frame comprises a cellulose material.

8. The aerosol - generating article according to any one of the preceding claims, wherein the frame comprises a biodegradable material.

9. The aerosol - generating article according to any one of the preceding claims, wherein the aerosol - generating substrate is planar.

10. The aerosol - generating article according to any one of claims 2 to 9, wherein the aerosol - generating substrate has a thickness less than the thickness of the peripheral wall.

11. The aerosol - generating article according to any one of the preceding claims, wherein the substrate has a top - surface area, the opening has a cross - sectional area, and the substrate top - surface area is less than the opening cross - sectional area.

12. The aerosol - generating article according to any one of the preceding claims, wherein the substrate has a top - surface area, the opening has a cross - sectional area, and the ratio of the substrate top - surface area to the opening cross - sectional area is at least about 1:

2.

13. The aerosol - generating article according to any one of the preceding claims, wherein the aerosol - generating substrate comprises a first aerosol - generating segment and a second aerosol - generating segment, the first aerosol - generating segment comprising a first aerosol - generating substrate and the second aerosol - generating segment comprising a second aerosol - generating substrate.

14. The aerosol - generating article according to any one of the preceding claims, wherein the first aerosol - generating substrate has one or both of a lower aerosol - forming agent content and a lower bulk density compared to the second aerosol - generating substrate.

15. An aerosol - generating system, comprising: An apparatus, the apparatus having a heating element configured to heat an aerosol-forming substrate to form an aerosol, and a device housing defining a chamber; and An aerosol-generating article according to any one of the preceding claims; wherein the aerosol-generating article is disposed in the chamber of the device housing to define a flow passage between the device housing and a frame of the article, the flow passage extending from the inlet to the outlet.

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