Aerosol-generating article

Abstract

An aerosol-generating article (100, 200, 300, 400, 500, 600, 700, 800) for use with an aerosol-generating device is provided. The aerosol-generating article comprises a substantially planar upper surface (110) and a substantially planar lower surface (120). The upper surface (110) and the lower surface (120) are vertically spaced apart from each other by a height defined in the z-direction. The aerosol-generating article (100) further comprises an aerosol-forming substrate and one or more susceptor materials (310, 320, 570, 624, 625, 870). The one or more susceptor materials are arranged in thermal communication with the aerosol-forming substrate.

Description

[0001] The present disclosure relates to an aerosol-generating article comprising an aerosol-forming substrate.

[0002] Typical aerosol-generating articles may resemble conventional cigarettes. For example, such an aerosol-generating article may be a substantially cylindrical article that includes an aerosol-forming substrate and other components such as a mouthpiece filter element, all of which are wrapped in cigarette paper. The dimensions of typical aerosol-generating articles are generally similar to those of conventional cigarettes.

[0003] Studies have shown that in such typical aerosol-generating articles that include a rod of aerosol-forming substrate, a majority of the rod of aerosol-forming substrate may not be sufficiently heated during use to form an aerosol. This is undesirable because this portion of the rod of aerosol-forming substrate affects the manufacturing and shipping costs of the aerosol-generating article but does not affect the aerosol delivered to the end user. This may be the case regardless of the manner in which the aerosol-forming substrate is heated, e.g., whether a resistive heater or an inductive heater is used, and regardless of whether the rod of aerosol-forming substrate is heated from the inside or the outside.

[0004] It is an object of the present disclosure to provide an aerosol-generating article in which a greater portion of the aerosol-forming substrate of the aerosol-generating article is sufficiently heated during use to form an aerosol.

[0005] According to the present disclosure, there can be provided an aerosol-generating article comprising an aerosol-forming substrate for generating an aerosol, the aerosol-generating article being a planar aerosol-generating article having a base defined by a length extending in the x direction, a width extending in the y direction, and a height extending in the z direction. The aerosol-generating article may further comprise one or more susceptor materials arranged in thermal communication with the aerosol-forming substrate.

[0006] According to the present disclosure, there can be provided an aerosol-generating article comprising an aerosol-forming substrate for generating an aerosol, the aerosol-generating article including a substantially planar upper surface defined by a length extending in the x direction and a width extending in the y direction, and a substantially planar lower surface defined by a length extending in the x direction and a width extending in the y direction. The substantially planar upper surface and the substantially planar lower surface may be vertically spaced apart from each other by a height defined in the z direction. The aerosol-generating article may further comprise one or more susceptor materials arranged in thermal communication with the aerosol-forming substrate.

[0007] According to the present disclosure, an aerosol - generating article for use with an aerosol - generating device can be provided. For example, the aerosol - generating article can be as described in any of the preceding paragraphs. The aerosol - generating article can include a substantially planar upper surface and a substantially planar lower surface. The upper surface and the lower surface can be vertically spaced apart from each other by a height defined in the z - direction. The aerosol - generating article can further include an aerosol - forming substrate and one or more susceptor materials. The one or more susceptor materials can be arranged in thermal communication with the aerosol - forming substrate.

[0008] The substantially planar upper surface can be defined by a length extending in the x - direction and a width extending in the y - direction.

[0009] The substantially planar lower surface can be defined by a length extending in the x - direction and a width extending in the y - direction.

[0010] The one or more susceptor materials can be used as heaters for imparting heat to the aerosol - generating article. Heating of the one or more susceptor materials can occur when the aerosol - generating article is placed within a varying magnetic field, where the varying magnetic field causes heating of the (one or more) susceptor materials by one or both of eddy - current heating and hysteresis. Such a varying magnetic field can be caused by an alternating current supplied to an inductor coil. Preferably, the inductor coil forms a part of the aerosol - generating device to which the aerosol - generating article can be coupled.

[0011] The aerosol - generating article of the present disclosure is generally flat and thin. Providing a generally flat and thin aerosol - generating article in combination with one or more susceptor materials arranged in thermal communication with the aerosol - forming substrate provides rapid and efficient heating of the aerosol - forming substrate and improved uniformity in through - thickness heating. The aerosol - forming substrate is preferably porous and / or of low density, thereby reducing the resistance to airflow through the aerosol - forming substrate (e.g., in the case where the aerosol - generating article has an airflow path extending through the aerosol - generating article). Preferably, the aerosol - generating article does not contain any single - use plastics, thereby providing an aerosol - generating article with improved sustainability.

[0012] Preferably, the one or more susceptor materials can be in direct contact with the aerosol - forming substrate.

[0013] Advantageously, the one or more susceptor materials can be included within the aerosol - forming substrate. Particles of the susceptor material can be dispersed within the aerosol - forming substrate.

[0014] The one or more susceptor materials can be included within the aerosol - generating article as one or more susceptor material strips, wires, or filaments. The one or more susceptor material strips, wires, or filaments can be located within the airflow path of the aerosol - generating article.

[0015] One or more susceptor materials may be included within the aerosol - generating article as one or more susceptor material sheets or layers. The one or more susceptor material sheets or layers may be located within the airflow path of the aerosol - generating article or at least partially define the airflow path of the aerosol - generating article. The one or more susceptor material sheets or layers may cover an external portion of the aerosol - generating article. The one or more susceptor material sheets or layers may form a structural component of the aerosol - generating article. At least one of the one or more susceptor material sheets or layers may be formed as a web of susceptor material.

[0016] Advantageously, the aerosol - generating article may include a plurality of susceptor regions spaced apart from one another and arranged in thermal communication with the aerosol - forming substrate, the plurality of susceptor regions comprising or consisting of one or more susceptor materials. The spacing of the different susceptor regions from one another allows for selective heating of different regions or portions of the aerosol - forming substrate by different ones of the susceptor regions within the susceptor regions. Suitably, the plurality of susceptor regions may be spaced apart from one another in the x - direction. The plurality of susceptor regions may include one or more susceptor materials overlying or included within a paper - based substrate or the aerosol - forming substrate.

[0017] (A) susceptor material(s) may comprise one or more materials selected from: aluminum, iron and iron alloys, nickel and nickel alloys, cobalt alloys, stainless steel alloys, copper alloys, carbon, expanded carbon, and graphite.

[0018] The upper surface and the lower surface may be parallel to each other.

[0019] The aerosol - generating article may extend along its length between a distal end and a proximal end. The aerosol - forming substrate may extend along at least a portion of the length of the aerosol - generating article. The aerosol - forming substrate may extend along a portion of the length of the aerosol - generating article and be positioned closer to the distal end than to the proximal end. In other embodiments, the aerosol - forming substrate may extend along the entire length of the aerosol - generating article. The aerosol - forming substrate may extend to the distal end. The proximal end may be the mouth - end of the aerosol - generating article.

[0020] An aerosol-generating article according to the present disclosure may preferably be a substantially flat article or a substantially planar article. Such articles have a large base area relative to the volume of the article. Advantageously, the larger base area may provide a larger surface area for heating by a planar heater of an aerosol-generating device. Advantageously, the smaller height may allow for a smaller temperature gradient or temperature difference across the height of the aerosol-generating article during heating. For example, in the case where the base of the aerosol-generating article is in contact with and heated by a planar heater, if the spacing or height between the base and the upper surface is small, there may be a small temperature difference between the base and the upper surface opposite the base. Advantageously, this may allow a greater proportion of the aerosol-forming substrate of the aerosol-generating article to be heated to the temperature at which aerosol is released while minimizing the risk of the hottest part of the substrate closest to the heater burning. Alternatively or additionally, this may reduce the time required to sufficiently heat the aerosol-forming substrate to release aerosol.

[0021] An aerosol-generating article according to any aspect disclosed herein may have an airflow path extending through the aerosol-generating article. The aerosol-generating article may have an airflow path defined to pass through the aerosol-generating article from one side of the aerosol-generating article to the other side in the x / y plane. The aerosol-generating article preferably has a draw resistance (RTD) of less than 20 millimeters of water, such as less than 10 millimeters of water, in the direction of the airflow path. Preferably, the aerosol-generating article has an RTD of less than 20 millimeters of water, such as less than 10 millimeters of water, in at least one direction in the x / y plane of the aerosol-generating article. An aerosol-generating article having a low-resistance airflow path may allow for good airflow management and allow the aerosol to be more effectively extracted from the aerosol-generating article and directed to the user.

[0022] Unless otherwise stated, the draw resistance (RTD) is measured according to ISO 6565-2015. The RTD refers to the pressure required to force air through the full length of a component, such as an aerosol-generating article. The terms "pressure drop" or "draw resistance" of a component or article may also refer to "resistance to draw". Such terms generally refer to measurements made according to ISO 6565-2015 and are typically made in a test at a temperature of approximately 22 degrees Celsius, a pressure of approximately 101 kPa (approximately 760 Torr), and a relative humidity of approximately 60% at a volumetric flow rate of approximately 17.5 milliliters per second at the output or downstream end of the component being measured.

[0023] An aerosol-generating article according to any aspect disclosed herein may include a substantially planar upper surface and a lower surface. A vertical separation between the substantially planar upper surface and the lower surface may define a height (e.g., z-dimension) of the aerosol-generating article. An airflow channel may be defined between the substantially planar upper surface and the lower surface. The height of the aerosol-generating article may be less than 5 mm, such as between 1.5 mm and 5 mm, such as between 1.5 mm and 4 mm, such as between 1.5 mm and 3 mm, such as between 1.5 mm and 2 mm. One or both of the substantially planar upper surface and the lower surface may include an aerosol-forming substrate. The aerosol-generating article may include an upper layer and a lower layer, at least one of the upper layer and the lower layer includes or consists of an aerosol-forming substrate, the upper layer forms the substantially planar upper surface, and the lower layer forms the substantially planar lower surface.

[0024] The aerosol-generating article may further include an intermediate layer disposed between the upper layer and the lower layer. The upper surface may define an outer surface of the upper layer, and the lower surface may define an outer surface of the lower layer. An airflow path may be defined to pass through the aerosol-generating article between a distal end and a proximal end of the aerosol-generating article in the x / y plane.

[0025] The draw resistance (RTD) of the aerosol-generating article along the airflow path may be less than 20 mm H2O.

[0026] Preferably, at least one of the upper layer, the intermediate layer, and the lower layer includes or consists of one or more sensor materials.

[0027] At least one of the upper layer, the intermediate layer, and the lower layer may include a plurality of sensor regions spaced apart from each other, the plurality of sensor regions including or consisting of one or more sensor materials. The different sensor regions being spaced apart from each other allows different regions or portions of the aerosol-forming substrate to be selectively heated by different sensor regions among the sensor regions. The plurality of sensor regions may be spaced apart from each other in the x-direction.

[0028] Both the upper layer and the lower layer may include or consist of an aerosol-forming substrate, and the intermediate layer may include or consist of one or more sensor materials.

[0029] Both the upper layer and the lower layer may include or consist of one or more sensor materials, and the intermediate layer may include or consist of an aerosol-forming substrate.

[0030] One or both of the upper layer and the lower layer may comprise or consist of an aerosol - forming substrate and one or more sensor materials. The one or more sensor materials may be dispersed within the aerosol - forming substrate of one or both of the upper layer and the lower layer.

[0031] One or both of the upper layer and the lower layer may comprise a sub - layer of an aerosol - forming substrate laminated with a sub - layer of one or more sensor materials. The sub - layer of the aerosol - forming substrate may define the inward - facing surface of the corresponding upper layer or lower layer.

[0032] The intermediate layer may comprise or consist of a paper - based substrate.

[0033] The intermediate layer may be free of an aerosol - forming substrate.

[0034] The intermediate layer may comprise or consist of an aerosol - forming substrate. The intermediate layer may also comprise one or more sensor materials.

[0035] The intermediate layer may be free of sensor materials.

[0036] One or more strips, lines or filaments of sensor material may be located within the airflow path defined by the intermediate layer.

[0037] A plurality of longitudinally - extending channels may be defined by corrugations between the upper layer and the intermediate layer and between the intermediate layer and the lower layer. The longitudinally - extending channels may extend together between a distal end and a proximal end in the x / y plane. One or more strips, lines or filaments of sensor material may be disposed within one or more of the corrugations.

[0038] In instances where one or more strips, lines or filaments of sensor material are located within the airflow path defined by the intermediate layer or are disposed within one or more of the corrugations, the intermediate layer may comprise or consist of an aerosol - forming substrate.

[0039] The intermediate layer may be fixed relative to at least one of the upper layer and the lower layer by an adhesive. For example, the adhesive may comprise guar gum. The adhesive may comprise an aerosol - forming material, such as homogenized tobacco slurry.

[0040] The intermediate layer may comprise corrugated elements.

[0041] The intermediate layer may comprise a plurality of corrugated elements. Two or more of the plurality of corrugated elements may be arranged in a vertical relationship with each other between the upper layer and the lower layer. One or more of the plurality of corrugated elements may comprise one or more sensor materials, and one or more of the other plurality of corrugated elements may comprise an aerosol - forming substrate. The intermediate layer may also comprise a planar element located between two of the plurality of corrugated elements. The planar element may comprise or consist of one or more sensor materials.

[0042] According to the present disclosure, an aerosol - generating article can be provided that includes a first planar layer, a second planar layer, and a corrugated layer disposed between the first planar layer and the second planar layer. At least one of the first planar layer, the second planar layer, and the corrugated layer can include or consist of an aerosol - forming substrate. The aerosol - generating article can also include one or more susceptor materials arranged in thermal communication with the aerosol - forming substrate. The susceptor material can be as described in any of the preceding paragraphs.

[0043] The use of a corrugated structure in an aerosol - generating article can advantageously allow for the production of an aerosol - generating article having a very low RTD while still being rigid enough for user handling. Additionally, the use of a corrugated structure can allow for the production of a low - density, low - RTD aerosol - generating article using high - speed production methods similar to those used for producing corrugated cardboard.

[0044] The aerosol - generating article can also include a planar frame positioned between an upper layer and a lower layer. The upper surface can define the outer surface of the upper layer, and the lower surface can define the outer surface of the lower layer. The planar frame can define a cavity. An airflow path can be defined as passing through the aerosol - generating article in the x / y plane, with the airflow path extending through the cavity.

[0045] The upper layer and the lower layer can be joined to opposite surfaces of the frame to overlie opposite ends of the cavity.

[0046] One or both of the upper layer and the lower layer can include or consist of one or more susceptor materials.

[0047] Advantageously, at least one of the upper layer and the lower layer can include a plurality of susceptor regions spaced apart from each other, the plurality of susceptor regions including or consisting of one or more susceptor materials. The plurality of susceptor regions can be spaced apart from each other in the x - direction.

[0048] One or both of the upper layer and the lower layer can include or consist of an aerosol - forming substrate and one or more susceptor materials.

[0049] One or more susceptor materials can be dispersed within the aerosol - forming substrate of one or both of the upper layer and the lower layer.

[0050] One or both of the upper layer and the lower layer can include a sub - layer of an aerosol - forming substrate laminated with a sub - layer of one or more susceptor materials. The sub - layer of the aerosol - forming substrate can define the inward - facing surface of the corresponding upper layer or lower layer.

[0051] The aerosol-generating article may also include one or more of particles, fragments, or sheets of an aerosol-forming substrate disposed within a cavity between an upper layer and a lower layer. The upper layer and the lower layer may be free of the aerosol-forming substrate.

[0052] A corrugated element may be disposed within a cavity between an upper layer and a lower layer. A plurality of longitudinally extending channels are defined by the corrugations between the upper layer and the corrugated element and between the corrugated element and the lower layer. The longitudinally extending channels may extend together between opposite ends of the frame in the x / y plane. One or more strips, threads, or filaments of sensor material are disposed within one or more of the corrugations. The corrugated element may include or consist of an aerosol-forming substrate. The outer layer and the inner layer may be free of the aerosol-forming substrate.

[0053] An airflow path may be at least partially defined by the frame. The frame may include an inlet airflow channel and an outlet airflow channel, the inlet airflow channel configured to permit air to flow into the cavity and the outlet airflow channel configured to permit air to flow out of the cavity. The inlet airflow channel and the outlet airflow channel may be defined at opposite ends of the frame. The inlet airflow channel may be defined in a first width edge of the frame and the outlet airflow channel defined in a second width edge of the frame.

[0054] According to the present disclosure, an aerosol-generating article may be provided that includes: a first planar outer surface; a second planar outer surface; a cavity; a frame positioned between the first planar outer surface and the second planar outer surface, the frame at least partially defining the cavity; an aerosol-forming substrate positioned between the first planar outer surface and the second planar outer surface; and an air inlet and an air outlet; and an airflow passage extending through the cavity between the air inlet and the air outlet. The aerosol-generating article may also include one or more sensor materials arranged in thermal communication with the aerosol-forming substrate. The sensor material may be as described in any of the preceding paragraphs.

[0055] The frame may include a peripheral wall at least partially defining or surrounding the cavity. The frame may include a peripheral wall completely defining or surrounding the cavity.

[0056] The aerosol-generating article may include a first planar outer layer and a second planar outer layer, wherein the first planar outer layer forms the first planar outer surface and the second planar outer layer forms the second planar outer surface. Optionally, at least one of the first planar outer layer, the second planar outer layer, and the frame may include or consist of an aerosol-forming substrate.

[0057] The cavity may be substantially empty.

[0058] The aerosol-forming substrate may be positioned within the cavity.

[0059] A corrugated layer may be positioned within the cavity.

[0060] The length (e.g., x-dimension) that an aerosol-generating article of any aspect of the present disclosure may have is between 10 millimeters and 100 millimeters, or between 10 millimeters and 50 millimeters, such as between 12 millimeters and 30 millimeters, such as between 14 millimeters and 26 millimeters, such as between 16 millimeters and 24 millimeters, such as between 18 millimeters and 22 millimeters, such as about 18 millimeters, or about 19 millimeters, or about 20 millimeters, or about 21 millimeters, or about 22 millimeters.

[0061] The width (e.g., y-dimension) that an aerosol-generating article may have is between 5 millimeters and 20 millimeters, such as between 8 millimeters and 18 millimeters, such as between 10 millimeters and 16 millimeters, such as between 11 millimeters and 15 millimeters, such as between 12 millimeters and 14 millimeters, such as about 13 millimeters.

[0062] The height (e.g., z-dimension) that an aerosol-generating article may have is between 1 millimeter and 10 millimeters, such as between 1.2 millimeters and 8 millimeters, such as between 1.4 millimeters and 7 millimeters, such as between 1.6 millimeters and 6 millimeters, such as between 1.7 millimeters and 5 millimeters, such as about 1.7 millimeters, or about 4.5 millimeters, or about 2 millimeters, or about 3 millimeters, or about 4 millimeters.

[0063] When viewed in a plan view, an aerosol-generating article of any aspect of the present disclosure may have a shape defining a polygon, a quadrilateral (e.g., a rectangle or a square), an oval, a circle, or a combination thereof. In the case where the aerosol-generating article includes substantially planar upper and lower surfaces, when viewed in a plan view, one or both of the upper and lower surfaces may have a shape defining a polygon, a quadrilateral (e.g., a rectangle or a square), an oval, a circle, or a combination thereof. When viewed in a plan view, the perimeter of the aerosol-generating article may be formed by a plurality of straight sides, a plurality of curved sides, or a combination of straight and curved sides. In the case where the aerosol-generating article includes substantially planar upper and lower surfaces, when viewed in a plan view, the perimeter of one or both of the upper and lower surfaces may have a shape defining a polygon, a quadrilateral (e.g., a rectangle or a square), an oval, a circle, or a combination thereof.

[0064] The aerosol-forming substrate may contain nicotine. The nicotine may be in the form of tobacco material or may be in the form of a nicotine extract.

[0065] Preferably, the aerosol-forming substrate comprises or consists of homogenized tobacco material, such as reconstituted tobacco material or cast leaf tobacco material.

[0066] The aerosol - forming matrix may comprise or consist of a solid aerosol - forming material. The aerosol - forming matrix may comprise a liquid aerosol - forming material, such as a liquid aerosol - forming material retained within a porous matrix. The aerosol - forming matrix may comprise a gel aerosol - forming material.

[0067] The aerosol - forming matrix may contain one or more aerosol - forming agents. Suitable aerosol - forming agents are well known in the art and include, but are not limited to, one or more aerosol - forming agents selected from the following: polyols such as propylene glycol, polyethylene glycol, triethylene 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. Particularly preferred for the aerosol - forming agent may be glycerol or include glycerol.

[0068] The aerosol - forming matrix may contain at least 1 wt%, 2 wt%, 5 wt%, 10 wt% or 15 wt% of the aerosol - forming agent. The aerosol - forming matrix may contain more than 15 wt% of the aerosol - forming agent, such as more than 20 wt%, or more than 25 wt%, or more than 30 wt%, or more than 40 wt% or more than 50 wt% of the aerosol - forming agent.

[0069] The aerosol - forming matrix may contain less than or equal to 30 wt%, less than or equal to 25 wt% or less than or equal to 20 wt% of the aerosol - forming agent. That is, the aerosol - forming matrix may have an aerosol - forming agent content of less than or equal to 30 wt%, less than or equal to 25 wt% or less than or equal to 20 wt%.

[0070] The aerosol - forming matrix may contain an aerosol - forming agent between 1 wt% and 30 wt%, between 1 wt% and 25 wt% or between 1 wt% and 20 wt%.

[0071] The aerosol - forming matrix may contain an aerosol - forming agent between 5 wt% and 30 wt%, between 5 wt% and 25 wt% or between 5 wt% and 20 wt%.

[0072] The aerosol - forming matrix may contain an aerosol - forming agent between 10 wt% and 30 wt%, between 10 wt% and 25 wt% or between 10 wt% and 20 wt%.

[0073] The aerosol - forming matrix may contain an aerosol - forming agent between 15 wt% and 30 wt%, between 15 wt% and 25 wt% or between 15 wt% and 20 wt%.

[0074] The aerosol-forming substrate may comprise at least 50 wt%, at least 60 wt%, or at least 70 wt% of an aerosol-forming agent.

[0075] The aerosol-forming substrate may comprise less than or equal to 85 wt%, less than or equal to 80 wt%, or less than or equal to 75 wt% of an aerosol-forming agent.

[0076] The aerosol-forming substrate may comprise from 50 wt% to 85 wt%, from 50 wt% to 80 wt%, or from 50 wt% to 75 wt% of an aerosol-forming agent.

[0077] The aerosol-forming substrate may comprise from 60 wt% to 85 wt%, from 60 wt% to 80 wt%, or from 60 wt% to 75 wt% of an aerosol-forming agent.

[0078] The aerosol-forming substrate may comprise from 70 wt% to 85 wt%, from 70 wt% to 80 wt%, or from 70 wt% to 75 wt% of an aerosol-forming agent.

[0079] The aerosol-forming substrate may comprise nicotine. The aerosol-forming material may comprise natural nicotine, or synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.

[0080] The aerosol-forming substrate may comprise at least 0.5 wt%, at least 1 wt%, at least 1.5 wt%, or at least 2 wt% of nicotine. That is, the aerosol-forming substrate may have a nicotine content of at least 0.5 wt%, at least 1 wt%, at least 1.5 wt%, or at least 2 wt%.

[0081] The aerosol-forming substrate may comprise one or more cannabinoid compounds such as one or more of the following: tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiol (CBD), cannabidiolic acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabigerol monomethyl ether (CBGM), cannabivarin (CBV), cannabidivarin (CBDV), tetrahydrocannabivarin (THCV), cannabichromene (CBC), cannabinol (CBL), cannabicyclol (CBCV), cannabigerovarin (CBGV), cannabielsoin (CBE), cannabinoid dibenzopyranocycloalkane (CBT). It may be preferred that the cannabinoid compound is CBD or THC. It may be particularly preferred that the cannabinoid compound is CBD.

[0082] The aerosol-forming substrate may comprise one or more flavorants. The one or more flavorants may comprise one or more of the following: one or more essential oils such as eugenol, peppermint oil, and spearmint oil; one or both of menthol and eugenol; one or both of anethole and linalool; and herbaceous materials. Suitable herbaceous materials include herbaceous plant leaves or other herbaceous materials from herbaceous plants including but not limited to mint (such as peppermint and spearmint), lemon balm, basil, cinnamon, lemon basil, chives, coriander, lavender, sage, tea, thyme, and caraway. The one or more flavorants may include tobacco materials.

[0083] In the final product state, the aerosol-forming substrate may have a moisture content of about 5% to 25%, preferably about 7% to 15%. For example, the aerosol-forming substrate may be a homogenized tobacco material having a moisture content of about 5% to 25%, preferably about 7% to 15% in the final product state.

[0084] The aerosol-forming substrate may comprise tobacco leaves; for example, a tobacco leaf blend of about 15% to 45%, preferably about 20% to 35%, which includes at least one of the following tobacco types: flue-cured tobacco; sun-cured tobacco; oriental tobacco. Tobacco materials such as tobacco leaves are preferably ground and sized to a particle size of about 100 to 380 mesh, preferably about 170 to 320 mesh.

[0085] "Tobacco type" means one of different tobacco varieties, for example based on different curing processes that the tobacco undergoes before being further processed into tobacco products.

[0086] Examples of flue-cured tobacco are Brazilian flue-cured tobacco, Indian flue-cured tobacco, Chinese flue-cured tobacco, US flue-cured tobacco (such as Virginia tobacco), and flue-cured tobacco from Tanzania.

[0087] Examples of oriental tobacco are Oriental Turkish, Greek Oriental, semi-oriental tobacco, but also fire-cured US Burley such as Perique and Rustica.

[0088] Examples of sun-cured tobacco are dark-cured Brazilian Galpao, Malawi Burley or other African Burleys, sun-cured or air-cured Indonesian Kasturi.

[0089] The aerosol-forming substrate may include cellulose fibers. For example, the aerosol-forming substrate may include about 1% to 15% cellulose fibers, preferably about 3% to 7% cellulose fibers. Preferably, the cellulose fibers may have a length of about 10 to 250 μm, preferably about 10 to 120 μm.

[0090] The aerosol-forming substrate may include organic fibers, such as non-tobacco fibers or tobacco fibers. For example, the aerosol-forming substrate may include from about 5% to 20%, preferably from about 7% to 15%, of tobacco fibers. The tobacco fibers are preferably derived from stems and / or stalks, which are classified into fibers having a length of about 10 to 350 μm, preferably about 10 to 180 μm. The aerosol-forming substrate may include from about 10% to 30%, preferably from about 15% to 25%, of non-tobacco organic fibers. For example, the organic fibers may be derived from cellulose, cotton, wood, tea plant varieties, which are by-products and secondary processing wastes of the tea industry. The organic fibers preferably have a length of about 10 to 400 μm, preferably about 10 to 200 μm.

[0091] The aerosol-forming substrate may contain a binder. For example, the aerosol-forming substrate may contain from about 1% to 10%, preferably from about 1% to 5%, of a binder, such as any of the common gums or pectins used in the food and beverage (F&B) industry. Preferred binders may be natural pectins (such as fruits, e.g., citrus) or tobacco pectin; guar gum, locust bean gum, hydroxyethyl and / or hydroxypropyl derivatives thereof; starches, such as modified or derivatized starches; alginates; methyl, ethyl, ethylhydroxymethyl, and carboxymethyl celluloses; dextran; and xanthan gum. The preferred binder is guar gum.

[0092] The aerosol-forming substrate may contain an organic plant glycerol agent. For example, the aerosol-forming substrate may contain from about 15% to 55%, preferably from about 20% to 35%, of plant materials, such as cloves, Echinacea, fennel, ginger, hawthorn berries, elderberries, Monarda, Verbascum leaves, nettle, plantain, turmeric, yarrow, and compounds thereof.

[0093] The aerosol-forming substrate may contain an organic plant extract. For example, the aerosol-forming substrate may contain from about 1% to 15%, preferably from about 2% to 7%, of any of the previously mentioned plant materials, as well as menthol (dl-menthol, C 10 H 20 O, 2-isopropyl-5-methylcyclohexanol) obtained from Chaerophyllum macrospermum, Mesosphaerum sidifolium, or other related plant varieties, and P-menthan-3-ol, which is any secondary alcohol that is a diastereoisomer of 5-methyl-2-(propan-2-yl)cyclohexan-1-ol.

[0094] The aerosol-forming substrate may contain a plant essential oil, for example, from about 0.5% to 5%, preferably from about 1% to 3%, of a plant essential oil, such as plant essential oils such as palm essential oil, coconut essential oil, and wood-based essential oil.

[0095] The aerosol-forming substrate preferably comprises an aerosol-forming agent, such as from about 5% to 35%, preferably from about 10% to 25%, of the aerosol-forming agent. Suitable aerosol-forming agents known in the art include: glycerol; monohydric alcohols, such as menthol; polyhydric alcohols, such as triethylene glycol; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids, such as the dimethyl esters thereof.

[0096] As used herein, the term "aerosol-generating article" may refer to an article capable of generating or releasing an aerosol.

[0097] As used herein, the term "aerosol-forming substrate" may refer to a substrate capable of releasing an aerosol or forming volatile compounds that can form an aerosol. Such volatile compounds can be released by heating the aerosol-forming substrate. The aerosol-forming substrate may comprise an aerosol-forming material. The aerosol-forming substrate may be adsorbed, coated, impregnated or otherwise loaded onto a carrier or support. The aerosol-forming substrate may suitably be part of an aerosol-generating article or a smoking article.

[0098] As used herein, the term "aerosol-generating device" may refer to a device for use with an aerosol-generating article to enable the generation or release of an aerosol.

[0099] As used herein, the term "aerosol-generating system" refers to a combination of an aerosol-generating device and one or more aerosol-forming articles for use with the device. The aerosol-generating system may include additional components, such as a charging unit for recharging the on-board power supply of an electrically operated or electronic aerosol-generating device.

[0100] As used herein, the term "aerosol-forming agent" 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-forming substrate or aerosol-generating article.

[0101] As used herein in reference to the present invention, the term "nicotine" is used to describe nicotine, nicotine base or nicotine salts.

[0102] As used herein in reference to the present invention, the terms "proximal", "distal", "upstream" and "downstream" are used to describe the relative positions of components or parts of components of an aerosol-generating article.

[0103] As used herein, the term "longitudinal" refers to the direction corresponding to the main longitudinal axis of the aerosol-generating article, which extends between the upstream end and the downstream end of the aerosol-generating article. During use, air may be drawn through the aerosol-generating article in the longitudinal direction.

[0104] As used herein, the term "sheet" refers to a layered element whose width and length are significantly greater than its thickness. The width of the sheet can be greater than 10 mm, preferably greater than 20 mm or 30 mm. In certain embodiments, a sheet of material for forming an aerosol-forming substrate as described herein can have a thickness between 10 μm and about 1000 μm, such as between 10 μm and about 300 μm.

[0105] As used herein, the term "homogenized tobacco material" encompasses any tobacco material formed by the coalescence of particles of tobacco material. A sheet or web of homogenized tobacco material is formed by coalescing particulate tobacco obtained by grinding or otherwise pulverizing one or both of tobacco leaves and tobacco stems. Additionally, the homogenized tobacco material can include small amounts of one or more of tobacco dust, tobacco fines, and other particulate tobacco by-products formed during the handling, processing, and transportation of tobacco. Sheets of homogenized tobacco material can be produced by casting, extrusion, papermaking processes, or any other suitable process known in the art.

[0106] The term "cast leaf" is used herein to refer to a product manufactured by a casting process based on casting a slurry comprising plant particles (e.g., clove particles or a mixture of tobacco particles and clove particles) and a binder (e.g., guar gum) onto a support surface such as a conveyor belt, 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, particulate plant material is produced by crushing, grinding, or milling parts of the plant. The particles produced from one or more plants are mixed with a liquid component, typically water, to form a slurry. Other components in the slurry can include fibers, binders, and aerosol formers. The particulate plant material can coalesce in the presence of a binder. The slurry is cast onto a support surface and dried into a sheet of homogenized plant material. Preferably, the homogenized plant material for use in the articles according to the invention can be produced by casting. Such homogenized plant material can include coalesced particulate plant material.

[0107] As used herein, draw resistance is expressed in pressure units of "mmH2O" or "mmWG" or "mm water column" and can be measured according to ISO 6565:2002.

[0108] The 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 can be combined with any one or more features of another example, embodiment, or aspect described herein.

[0109] Example Ex1: An aerosol - generating article for use with an aerosol - generating device, the aerosol - generating article including a substantially planar upper surface and a substantially planar lower surface, the upper surface and the lower surface being vertically spaced apart from each other by a height defined in the z - direction, the aerosol - generating article further including an aerosol - forming substrate and one or more sensor materials, the one or more sensor materials being arranged in thermal communication with the aerosol - forming substrate.

[0110] Example Ex2: The aerosol - generating article according to Ex1, wherein the one or more sensor materials are in direct contact with the aerosol - forming substrate.

[0111] Example Ex3: The aerosol - generating article according to any one of Ex1 or Ex2, wherein the one or more sensor materials are included within the aerosol - forming substrate.

[0112] Example Ex4: The aerosol - generating article according to Ex3, wherein the particles of the sensor material are dispersed within the aerosol - forming substrate.

[0113] Example Ex5: The aerosol - generating article according to any one of Ex1 to Ex4, wherein the one or more sensor materials are included within the aerosol - generating article as one or more strips, lines or filaments of sensor material.

[0114] Example Ex6: The aerosol - generating article according to Ex5, wherein one or more strips, lines or filaments of sensor material are located within the airflow path of the aerosol - generating article.

[0115] Example Ex7: The aerosol - generating article according to any one of Ex1 to Ex6, wherein the one or more sensor materials are included within the aerosol - generating article as one or more sheets or layers of sensor material.

[0116] Example Ex8: The aerosol - generating article according to Ex7, wherein one or more sheets or layers of sensor material are located within the airflow path of the aerosol - generating article or at least partially define the airflow path of the aerosol - generating article.

[0117] Example Ex9: The aerosol - generating article according to any one of Ex7 or Ex8, wherein one or more sheets or layers of sensor material cover an external portion of the aerosol - generating article.

[0118] Example Ex10: The aerosol - generating article according to any one of Ex7 to Ex9, wherein one or more sheets or layers of sensor material form a structural component of the aerosol - generating article.

[0119] Example Ex11: An aerosol-generating article according to any one of Ex7 to Ex10, wherein at least one of the one or more susceptor material sheets or layers is formed as a web of susceptor material.

[0120] Example Ex12: An aerosol-generating article according to any one of Ex1 to Ex11, comprising a plurality of susceptor regions spaced apart from each other and arranged in thermal communication with the aerosol-forming substrate, the plurality of susceptor regions comprising or consisting of one or more susceptor materials.

[0121] Example Ex13: The aerosol-generating article according to Ex12, wherein the plurality of susceptor regions are spaced apart from each other in the x direction.

[0122] Example Ex14: The aerosol-generating article according to any one of Ex12 or Ex13, wherein the plurality of susceptor regions comprise one or more susceptor materials overlying or included in a paper-based substrate or the aerosol-forming substrate.

[0123] Example Ex15: An aerosol-generating article according to any one of Ex1 to Ex14, wherein the susceptor material comprises one or more materials selected from the group consisting of: aluminum, iron and iron alloys, nickel and nickel alloys, cobalt alloys, stainless steel alloys, copper alloys, carbon, expanded carbon, and graphite.

[0124] Example Ex16: An aerosol-generating article according to any one of Ex1 to Ex15, wherein the upper surface and the lower surface are parallel to each other.

[0125] Example Ex17: An aerosol-generating article according to any one of Ex1 to Ex16, wherein the aerosol-generating article extends along its length between a distal end and a proximal end, the aerosol-forming substrate extends along at least a portion of the length of the aerosol-generating article, optionally, the aerosol-forming substrate extends along the entire length of the aerosol-generating article.

[0126] Example Ex18: The aerosol-generating article according to Ex17, wherein the aerosol-forming substrate extends along a portion of the length of the aerosol-generating article and is positioned closer to the distal end than to the proximal end.

[0127] Example Ex19: The aerosol-generating article according to any one of Ex17 or Ex18, wherein the aerosol-forming substrate extends to the distal end.

[0128] Example Ex20: An aerosol-generating article according to any one of Ex17 to Ex19, wherein the proximal end is the mouth end of the aerosol-generating article.

[0129] Example Ex21: An aerosol - generating article according to any one of Ex1 to Ex20, further comprising an intermediate layer disposed between an upper layer and a lower layer, wherein an upper surface defines an outer surface of the upper layer and a lower surface defines an outer surface of the lower layer, and an airflow path is defined to pass through the aerosol - generating article between a distal end and a proximal end of the aerosol - generating article in the x / y plane.

[0130] Example Ex22: An aerosol - generating article according to Ex21, wherein a draw resistance (RTD) of the aerosol - generating article along the airflow path is less than 20 millimeters of H2O.

[0131] Example Ex23: An aerosol - generating article according to any one of Ex21 or Ex22, wherein at least one of the upper layer, the intermediate layer, and the lower layer comprises or consists of one or more sensor materials.

[0132] Example Ex24: An aerosol - generating article according to Ex23, wherein at least one of the upper layer, the intermediate layer, and the lower layer comprises a plurality of sensor regions spaced apart from each other, the plurality of sensor regions comprising or consisting of one or more sensor materials.

[0133] Example Ex25: An aerosol - generating article according to Ex24, wherein the plurality of sensor regions are spaced apart from each other in the x - direction.

[0134] Example Ex26: An aerosol - generating article according to any one of Ex23 to Ex25, wherein both the upper layer and the lower layer comprise or consist of an aerosol - forming substrate, and the intermediate layer comprises or consists of one or more sensor materials.

[0135] Example Ex27: An aerosol - generating article according to any one of Ex23 to Ex25, wherein both the upper layer and the lower layer comprise or consist of one or more sensor materials, and the intermediate layer comprises or consists of an aerosol - forming substrate.

[0136] Example Ex28: An aerosol - generating article according to any one of Ex23 to Ex27, wherein one or both of the upper layer and the lower layer comprise or consist of an aerosol - forming substrate and one or more sensor materials.

[0137] Example Ex29: An aerosol - generating article according to Ex28, wherein one or more sensor materials are dispersed within the aerosol - forming substrate of one or both of the upper layer and the lower layer.

[0138] Example Ex30: An aerosol-generating article according to any one of Ex28 or Ex29, wherein one or both of the upper layer and the lower layer comprise a sub-layer of an aerosol-forming substrate laminated with a sub-layer of one or more sensor materials.

[0139] Example Ex31: An aerosol-generating article according to Ex30, wherein the sub-layer of the aerosol-forming substrate defines the inward-facing surface of the corresponding upper or lower layer.

[0140] Example Ex32: An aerosol-generating article according to any one of Ex28 to Ex31, wherein the intermediate layer comprises or consists of a paper-based substrate.

[0141] Example Ex33: An aerosol-generating article according to any one of Ex28 to Ex32, wherein the intermediate layer is free of an aerosol-forming substrate.

[0142] Example Ex34: An aerosol-generating article according to any one of Ex28 to Ex32, wherein the intermediate layer comprises or consists of an aerosol-forming substrate.

[0143] Example Ex35: An aerosol-generating article according to Ex34, wherein the intermediate layer further comprises one or more sensor materials.

[0144] Example Ex36: An aerosol-generating article according to any one of Ex28 to Ex34, wherein the intermediate layer is free of sensor materials.

[0145] Example Ex37: An aerosol-generating article according to any one of Ex21 to Ex36, wherein one or more sensor material strips, wires or filaments are located within an air flow path defined by the intermediate layer.

[0146] Example Ex38: An aerosol-generating article according to any one of Ex21 to Ex37, wherein a plurality of longitudinally extending channels are defined by corrugations between the upper layer and the intermediate layer and between the intermediate layer and the lower layer.

[0147] Example Ex39: An aerosol-generating article according to Ex38, wherein the longitudinally extending channels extend together between the distal end and the proximal end in the x / y plane.

[0148] Example Ex40: An aerosol-generating article according to any one of Ex38 or Ex39, wherein one or more sensor material strips, wires or filaments are disposed in one or more of the corrugations.

[0149] Example Ex41: An aerosol-generating article according to any one of Ex37 or Ex40, wherein the intermediate layer comprises or consists of an aerosol-forming substrate.

[0150] Example Ex42: An aerosol-generating article according to any one of Ex21 to Ex41, wherein the intermediate layer is fixed relative to at least one of the upper layer and the lower layer by an adhesive, for example wherein the adhesive comprises guar gum, optionally wherein the adhesive comprises an aerosol-forming material such as homogenized tobacco slurry.

[0151] Example Ex43: An aerosol-generating article according to any one of Ex21 to Ex42, wherein the intermediate layer comprises corrugated elements.

[0152] Example Ex44: An aerosol-generating article according to Ex43, wherein the intermediate layer comprises a plurality of corrugated elements, and two or more of the plurality of corrugated elements are arranged in a vertical relationship with each other between the upper layer and the lower layer.

[0153] Example Ex45: An aerosol-generating article according to Ex44, wherein one or more of the plurality of corrugated elements comprise one or more sensor materials, and one or more of the other plurality of corrugated elements comprise an aerosol-forming matrix.

[0154] Example Ex46: An aerosol-generating article according to any one of Ex44 or Ex45, wherein the intermediate layer further comprises a planar element, and the planar element is positioned between two of the plurality of corrugated elements.

[0155] Example Ex47: An aerosol-generating article according to Ex46, wherein the planar element comprises or consists of one or more sensor materials.

[0156] Example Ex48: An aerosol-generating article according to any one of Ex1 to Ex20, further comprising a planar frame positioned between the upper layer and the lower layer, an upper surface defining an outer surface of the upper layer, and a lower surface defining an outer surface of the lower layer, the planar frame defining a cavity, wherein an airflow path is defined to pass through the aerosol-generating article in the x / y plane, and the airflow path extends through the cavity.

[0157] Example Ex49: An aerosol-generating article according to Ex48, wherein the upper layer and the lower layer are joined to opposite surfaces of the frame to cover opposite ends of the cavity.

[0158] Example Ex50: An aerosol-generating article according to any one of Ex48 or Ex49, wherein one or both of the upper layer and the lower layer comprise or consist of one or more sensor materials.

[0159] Example Ex51: An aerosol-generating article according to Ex50, wherein at least one of the upper layer and the lower layer comprises a plurality of sensor regions spaced apart from each other, the plurality of sensor regions comprising or consisting of one or more sensor materials.

[0160] Example Ex52: An aerosol-generating article according to Ex51, wherein the plurality of sensor regions are spaced apart from each other in the x direction.

[0161] Example Ex53: An aerosol-generating article according to any one of Ex50 to Ex52, wherein one or both of the upper layer and the lower layer comprise or consist of an aerosol-forming substrate and one or more sensor materials.

[0162] Example Ex54: An aerosol-generating article according to Ex53, wherein one or more sensor materials are dispersed within the aerosol-forming substrate of one or both of the upper layer and the lower layer.

[0163] Example Ex55: An aerosol-generating article according to any one of Ex53 or Ex54, wherein one or both of the upper layer and the lower layer comprise a sublayer of an aerosol-forming substrate laminated with a sublayer of one or more sensor materials.

[0164] Example Ex56: An aerosol-generating article according to Ex55, wherein the sublayer of the aerosol-forming substrate defines the inward-facing surface of the corresponding upper or lower layer.

[0165] Example Ex57: An aerosol-generating article according to any one of Ex48 to Ex56, further comprising one or more of particles, debris, or sheets of an aerosol-forming substrate disposed within the cavity between the upper layer and the lower layer.

[0166] Example Ex58: An aerosol-generating article according to Ex57, wherein the upper layer and the lower layer are free of an aerosol-forming substrate.

[0167] Example Ex59: An aerosol-generating article according to any one of Ex48 to Ex58, wherein a corrugated element is disposed within the cavity between the upper layer and the lower layer.

[0168] Example Ex60: An aerosol-generating article according to Ex59, wherein a plurality of longitudinally extending channels are defined by the corrugations between the upper layer and the corrugated element and between the corrugated element and the lower layer.

[0169] Example Ex61: An aerosol-generating article according to Ex60, wherein the longitudinally extending channels extend together between opposite ends of the frame in the x / y plane.

[0170] Example Ex62: An aerosol-generating article according to any one of Ex60 or Ex61, wherein one or more receptor material strips, threads or filaments are disposed in one or more of the corrugations.

[0171] Example Ex63: An aerosol-generating article according to any one of Ex59 to Ex62, wherein the corrugated element comprises or consists of an aerosol-forming substrate.

[0172] Example Ex64: An aerosol-generating article according to Ex63, wherein the outer layer and the inner layer do not contain an aerosol-forming substrate.

[0173] Example Ex65: An aerosol-generating article according to any one of Ex48 to Ex64, wherein the airflow path is at least partially defined by the frame.

[0174] Example Ex66: An aerosol-generating article according to Ex65, wherein the frame comprises an inlet airflow channel and an outlet airflow channel, the inlet airflow channel being configured to permit air to flow into the cavity and the outlet airflow channel being configured to permit air to flow out of the cavity.

[0175] Example Ex67: An aerosol-generating article according to Ex66, wherein the inlet airflow channel and the outlet airflow channel are defined at opposite ends of the frame.

[0176] Example Ex68: An aerosol-generating article according to any one of Ex66 or Ex67, wherein the inlet airflow channel is defined in a first width edge of the frame and the outlet airflow channel is defined in a second width edge of the frame.

[0177] The examples will now be further described with reference to the accompanying drawings, in which:

[0178] Figure 1 is a perspective side view of an aerosol-generating article according to a first embodiment of the present disclosure;

[0179] Figure 2 is a perspective side view of an aerosol-generating article according to a second embodiment of the present disclosure;

[0180] Figure 3 is a schematic end view of an aerosol-generating article according to a third embodiment of the present disclosure;

[0181] Figure 4 is Figure 3 a schematic side view of an aerosol-generating article of

[0182] Figure 5 is Figure 3 a schematic plan view of an aerosol-generating article of

[0183] Figure 6 shows a schematic view of a corrugated element used in an aerosol - generating article as Figure 3 ;

[0184] Figure 7 is a schematic end - view of an aerosol - generating article according to a fourth embodiment of the present disclosure;

[0185] Figure 8 is a schematic end - view of an aerosol - generating article according to a fifth embodiment of the present disclosure;

[0186] Figure 9 shows a perspective view of an aerosol - generating article according to a sixth embodiment of the present disclosure;

[0187] Figure 10 shows Figure 9 an exploded perspective view of an aerosol - generating article;

[0188] Figure 11 shows Figure 9 another exploded perspective view of an aerosol - generating article;

[0189] Figure 12 shows Figure 9 a schematic cross - sectional side view of an aerosol - generating article;

[0190] Figure 13 shows Figure 9 a schematic longitudinal cross - sectional view of an aerosol - generating article;

[0191] Figure 14 shows an exploded perspective view of an aerosol - generating article according to a seventh embodiment of the present disclosure;

[0192] Figure 15 shows Figure 14 a schematic cross - sectional side view of an aerosol - generating article;

[0193] Figure 16 shows Figure 14 a schematic lateral cross - sectional view of an aerosol - generating article;

[0194] Figure 17 shows a schematic cross - sectional side view of an aerosol - generating article according to an eighth embodiment of the present disclosure, the aerosol - generating article being a Figures 14 to 16 variant of the aerosol - generating article;

[0195] Figures 18A to 18C is a cross - sectional view of different composite structures containing one or more sensor materials for use in an aerosol - generating article of the present disclosure (such as Figures 1 to 17 the aerosol - generating article);

[0196] Figure 19 A perspective view of a composite structure including spaced-apart sheets of sensor material for use in an aerosol-generating article of the present disclosure.

[0197] Figure 1 A perspective side view of an aerosol-generating article 100 according to a first embodiment of the present disclosure is shown. The aerosol-generating article 100 has a flat or planar upper surface 110 and a lower surface 120.

[0198] The aerosol-generating article 100 includes an aerosol-forming substrate and one or more sensor materials (not shown). In one embodiment, the aerosol-generating article 100 may consist essentially of the aerosol-forming substrate and one or more sensor materials. In another embodiment, the aerosol-forming substrate and one or more sensor materials may be a subset of the plurality of component parts of the aerosol-generating article 100. The aerosol-forming substrate may be encapsulated within the interior of the aerosol-generating article 100. The aerosol-forming substrate may at least partially define the exterior of the aerosol-generating article 100; for example, one or both of the upper surface 110 and the lower surface 120 may include or consist of the aerosol-forming substrate. One or more sensor materials may be encapsulated within the interior of the aerosol-generating article 100. One or more sensor materials may at least partially define the exterior of the aerosol-generating article 100; for example, one or both of the upper surface 110 and the lower surface 120 may include or consist of one or more sensor materials. In additional embodiments, one or more sensor materials and the aerosol-forming substrate may be combined to form a composite structure.

[0199] The (s)ensor material(s) may be formed of stainless steel or aluminum.

[0200] A suitable aerosol-forming substrate may be homogenized tobacco.

[0201] The aerosol-generating article 100 has a length extending in the x-dimension of 80 millimeters, a width extending in the y-dimension of 15 millimeters, and a height (which may also be referred to as thickness) extending in the z-dimension of 3.6 millimeters.

[0202] Figure 2A perspective side view of an aerosol-generating article 200 according to a second embodiment of the present disclosure is shown, the aerosol-generating article being a variant of the aerosol-generating article 100. Like the aerosol-generating article 100, the aerosol-generating article 200 also includes one or more susceptor materials. Features that are the same as those of the aerosol-generating article 100 are denoted by the same reference numerals. An airflow path 230 is defined as passing through the aerosol-generating article 200 between an upper surface 110 and a lower surface 120. The airflow path 230 extends between opposite first and second ends 201 and 202 of the aerosol-generating article 200. The first end 201 may define a distal end of the aerosol-generating article 200, and the second end 202 may define a proximal end of the aerosol-generating article. The airflow path 230 may be directed towards a user's mouth to allow the user to inhale an aerosol generated by heating an aerosol-forming substrate of the aerosol-generating article 200.

[0203] Figure 3 , 4 Figures 5, ,

[0204] and respectively show an end view, a side view and a plan view of an aerosol-generating article 300 according to a third embodiment of the present disclosure. The aerosol-generating article 300 includes a planar upper layer 310, a planar lower layer 320, and an intermediate or separating layer 340 disposed between the upper layer 310 and the lower layer 320.

[0204] The planar upper layer 310 is formed from a sheet of susceptor material (e.g., a stainless steel or aluminum sheet) having a thickness of 50 microns. The planar lower layer 320 is formed from a sheet of susceptor material (e.g., a stainless steel or aluminum sheet) having a thickness of 50 microns. The intermediate layer 340 is a corrugated element formed from a corrugated aerosol-forming substrate sheet 345. A suitable aerosol-forming substrate may be homogenized tobacco. Thus, the intermediate layer 340 may be formed from a sheet of corrugated homogenized tobacco material 345.

[0205] Figure 6 Figure shows the corrugated aerosol-forming substrate sheet 345. The corrugations have an amplitude 346 of 3 mm and a wavelength 347 of 3 mm. The aerosol-forming substrate sheet 345 forming the intermediate layer 340 has a thickness of 150 microns.

[0206] The intersection points 351, 352 between the upper layer 310 and the intermediate layer 340 and between the lower layer 320 and the intermediate layer 340 include an adhesive that joins the respective layers.

[0207] The aerosol-generating article 300 has a length extending in the x dimension of 80 mm, a width extending in the y dimension of 15 mm, and a height (or thickness) extending in the z dimension of 3.6 mm.

[0208] The corrugations of the intermediate layer 340 form a first set of longitudinally extending channels 361 defined by the upper layer 310 and the intermediate layer 340, and a second set of longitudinally extending channels 362 defined by the lower layer 320 and the intermediate layer 340. The first set of longitudinally extending channels 361 and the second set of longitudinally extending channels 362 extend through the length of the aerosol-forming substrate between the proximal end 371 and the distal end 372 of the substrate 345. The longitudinally extending channels 361, 362 define an air flow path through the substrate 345. Thus, the air flow path traverses both sides of the aerosol-forming substrate sheet 345. The porosity of the aerosol-generating article along the air flow path is about 90%. This provides a very low draw resistance (RTD) of less than 5 mmH2O. In fact, the RTD is close to zero.

[0209] The aerosol-forming substrate 345 can be any suitable aerosol-forming substrate sheet.

[0210] During use of the aerosol-generating article 300, the article is positioned within a time-varying magnetic field. The change of the magnetic field over time causes heating of the receptor materials of the planar upper layer 310 and the planar lower layer 320 (by one or both of eddy current heating or hysteresis). The time-varying magnetic field can be generated by supplying an alternating current to an inductor coil of an aerosol-generating device (not shown) to which the aerosol-generating article 300 can be coupled. The heating of the receptor materials of the planar upper layer 310 and the planar lower layer 320 in turn causes heating of the corrugated aerosol-forming substrate sheet 345. The heating of the aerosol-forming substrate 345 causes the aerosol-forming substrate 345 to release volatile compounds, which are then entrained in the air drawn through the channels 361, 362 via the distal end 372. The volatile compounds then cool and condense to form an aerosol, which can be drawn out of the channels 361, 362 of the aerosol-generating article 300 via the proximal end 371.

[0211] Figure 7 A end view of an aerosol-generating article 400 according to a fourth embodiment of the present disclosure is shown, which is a variant of the aerosol-generating article 300. Features that are the same as those of the aerosol-generating article 300 are denoted by the same reference numerals. For the aerosol-generating article 400, the planar upper layer 310 is formed of an aerosol-forming substrate sheet having a thickness of 150 microns, the planar lower layer 320 is formed of an aerosol-forming substrate sheet having a thickness of 150 microns, and the intermediate layer 340 is a corrugated receptor element formed of a corrugated stainless steel or aluminum sheet having a thickness of 50 microns. A suitable aerosol-forming substrate for the planar upper layer 310 and the lower layer 320 can be homogenized tobacco. Thus, the planar upper layer 310 and the planar lower layer 320 can be formed of a homogenized tobacco material.

[0212] Figure 8A front view of an aerosol - generating article 500 according to a fifth embodiment of the present disclosure is shown. The aerosol - generating article is a variant of the aerosol - generating articles 300, 400. Features that are the same as those of the aerosol - generating articles 300, 400 are denoted by the same reference numerals. For the aerosol - generating article 500, the planar upper layer 310 is formed of a paper sheet material having a thickness of 300 micrometers, the planar lower layer 320 is formed of a paper sheet material having a thickness of 300 micrometers, and the intermediate layer 340 is a corrugated element formed of a corrugated aerosol - forming matrix sheet material 345 having a thickness of 150 micrometers. A suitable aerosol - forming matrix for the intermediate layer 340 can be homogenized tobacco. Thus, the intermediate layer 340 can be formed of a sheet of corrugated homogenized tobacco material 345. The longitudinal sensor strips 570 are located within each of the longitudinally - extending channels 361. The sensor strips 570 can be formed of stainless steel or aluminum.

[0213] Figure 9 An aerosol - generating article 600 according to a sixth embodiment of the present disclosure is shown. The aerosol - generating article 600 includes a first planar outer layer 624 that forms a first planar outer surface 621, a second planar outer layer 625 that forms a second planar outer surface 622, and a frame 650 positioned between the first planar outer layer 624 and the second planar outer layer 625. The second planar outer surface 622 is positioned parallel to the first planar outer surface 621.

[0214] Figure 10 and 11 shows Figure 9 an exploded view of the aerosol - generating article 600. The frame 650 defines and at least partially bounds a cavity 630. Figure 10 A view of the cavity 630 in an empty state is shown. Figure 11 A view of the cavity 630 filled with an aerosol - forming matrix 640 is shown. Figure 12 and 13 show a corresponding cross - sectional view and a longitudinal cross - sectional view of the aerosol - generating article 600 when the cavity 630 is filled with the aerosol - forming matrix 640.

[0215] The first planar outer layer 624 and the second planar outer layer 625 are made of a sensor material sheet (e.g., a stainless - steel or aluminum sheet) having a thickness of 35 micrometers, and are in physical contact with and bonded to the frame 650. The first planar outer layer 624 overlies a first end of the cavity 630 and forms a first cavity end wall 631. The second planar outer layer 625 overlies a second end of the cavity 630 and forms a second cavity end wall 632, and the second cavity end wall 632 is opposite to the first cavity end wall 631. That is, the frame 650, the first planar outer layer 624, and the second planar outer layer 625 together define the cavity 630.

[0216] The frame 650 has a hollow cuboid shape and is made of cardboard. The frame 650 defines an aperture extending through the height (also referred to as thickness) of the frame 650, and the aperture at least partially forms the cavity 630 of the aerosol-generating article 600. The frame 650 includes a peripheral wall 651 defining the cavity 630. The peripheral wall 651 includes a front wall 613 and a rear wall 614. More specifically, the peripheral wall 651 is defined by the inner lateral surface 652 of the frame 450 and the outer lateral surface 653 of the frame 650. The inner lateral surface 652 of the peripheral wall 651 at least partially defines the perimeter of the cavity 630. The outer lateral surface 653 of the peripheral wall 651 at least partially defines the perimeter of the aerosol-generating article 600. The peripheral wall 651 has a radial thickness of about 5 millimeters measured between the inner lateral surface 652 of the frame 650 and the outer lateral surface 653 of the frame 650.

[0217] The air inlet 611 and the air outlet 612 are defined by the peripheral wall 651 of the frame 650 and extend through the peripheral wall. More specifically, the air inlet 611 extends through the front wall 613, and the air outlet 612 extends through the rear wall 614. The air inlet 611 and the air outlet 612 have an equivalent diameter of 5 millimeters. The air flow path extends through the cavity 630 between the air inlet 611 and the air outlet 612. As Figures 11 to 13 shown, the aerosol-forming substrate 640 is positioned within the cavity 630. The aerosol-forming substrate 640 includes an aerosol-generating material in the form of tobacco cut filler and has an aerosol-forming agent content of 5 wt% on a dry weight basis. As shown, the aerosol-forming substrate 640 fills the entire volume of the cavity 630.

[0218] The aerosol-generating article 600 has a cuboid shape and has a height (or thickness) extending in the z-dimension of 8 millimeters (as measured between the first planar outer surface 621 and the second planar outer surface 622), a width extending in the y-dimension of 40 millimeters, and a length extending in the x-dimension of 60 millimeters. The frame 650 has a height (or thickness) extending in the z-dimension of 7.93 millimeters, a width extending in the y-dimension of 40 millimeters, and a length extending in the x-dimension of 60 millimeters. The cavity 630 has a height (or thickness) extending in the z-dimension of 7.93 millimeters, a width extending in the y-dimension of 39.93 millimeters, and a length extending in the x-dimension of 52 millimeters.

[0219] Figure 14 An aerosol-generating article 700 according to a seventh embodiment of the present disclosure is shown. Features that are the same as those of the aerosol-generating article 600 are referred to by the same reference numerals. The aerosol-generating article 700 differs from the aerosol-generating article 600 in that the aerosol-forming substrate is in the form of a sheet of aerosol-generating material 740, in particular a corrugated homogenized tobacco material sheet. Figure 15 and16 Shows Figure 14 corresponding transverse and lateral cross-sectional views of the aerosol-generating article 700.

[0220] The corrugated homogenized tobacco material sheet 740 includes a plurality of parallel corrugations having a plurality of substantially parallel peaks 743 and valleys 744. As Figure 15 seen, the plurality of parallel corrugations are defined by a corrugation profile that is sinusoidal. The plurality of parallel corrugations have a corrugation wavelength of approximately 4.6 mm. As shown by the peaks 743 and valleys 744 that coincide with the first cavity end wall 631 and the second cavity end wall 632, respectively, the corrugation amplitude is substantially the same as the height (or thickness) of the cavity 630.

[0221] The plurality of parallel corrugations form a plurality of channels 745 between the aerosol-forming material sheet 740 and the first cavity end wall 631, and a plurality of channels 746 between the aerosol-forming material sheet 740 and the second cavity end wall 632. The plurality of channels 745, 746 extend in the longitudinal direction of the aerosol-generating article 700 and form at least a portion of the air flow path extending between the air inlet 611 and the air outlet 612.

[0222] During use of each aerosol-generating article of the aerosol-generating articles 600, 700, the article is positioned within a time-varying magnetic field. The time-varying nature of the magnetic field causes heating of the susceptor material of the first planar outer layer 624 and the second planar outer layer 625 (by one or both of eddy current heating or hysteresis). The time-varying magnetic field can be generated by supplying an alternating current to an inductor coil of an aerosol-generating device (not shown) to which the aerosol-generating articles 600, 700 can be coupled. Heating of the susceptor material of the first planar outer layer 624 and the second planar outer layer 625 in turn causes: i) for the aerosol-generating article 600, heating of the aerosol-forming substrate 640 disposed within the cavity 630, or ii) for the aerosol-generating article 700, heating of the corrugated aerosol-forming material sheet 740. Heating of the aerosol-forming substrate 640 / aerosol-forming material 740 causes the aerosol-forming substrate 640 / aerosol-forming material 740 to release volatile compounds, which are then entrained in the air drawn into the cavity 630 through the air inlet 611. The volatile compounds then cool and condense to form an aerosol, which can be drawn out of the aerosol-generating articles 600, 700 through the air outlet 612.

[0223] Figure 17Shows a cross-section of an aerosol-generating article 800 according to an eighth embodiment of the present disclosure, the aerosol-generating article being a variant of aerosol-generating articles 600, 700. Features that are the same as those of aerosol-generating articles 600, 700 are denoted by the same reference numerals. The aerosol-generating article 800 includes all the features of the aerosol-generating article 700 (such as the corrugated aerosol-forming material sheet 740), but additionally includes longitudinal sensor strips 870 within each of the longitudinally extending channels 745 defined in the longitudinally extending channels between the aerosol-forming material sheet 740 and the first chamber end wall 631. The sensor strips 870 may be formed of stainless steel or aluminum. In Figure 17 a variant of the aerosol-generating article 800, the first planar outer layer 624 and the second planar outer layer 625 may be formed of cigarette paper (instead of a sensor material sheet).

[0224] As shown for aerosol-generating articles 300, 400, 500, 600, 700, 800, different component parts of the aerosol-generating article may be formed of a sensor material, where the sensor material is located at various different positions within the aerosol-generating article.

[0225] Figures 18A to 18C Shows various alternative configurations in which the sensor material is integrated or combined with another material to form a composite structure containing the sensor material.

[0226] Figure 18A Shows an embodiment of a composite structure 1000 suitable for use in an aerosol-generating article (such as any one of aerosol-generating articles 100, 200, 300, 400, 500, 600, 700, 800). The composite structure 1000 has a laminated structure defined by a first layer 1011 overlying a second layer 1012. The first layer 1011 is formed of a sensor material sheet (e.g., a stainless steel or aluminum sheet). The second layer 1012 is formed of a paper-based substrate sheet. The paper-based substrate may be a substrate formed of paper or cardboard. In an alternative embodiment, an aerosol-forming matrix may be used in place of the paper-based substrate for the second layer 1012. For example, the composite structure 1000 may be used to form the planar upper layer 310 or the planar lower layer 320 of the aerosol-generating article 300 (see Figure 3 ). In another example, the composite structure 1000 may be used to form the corrugated intermediate layer 340 of the aerosol-generating article 400 (see Figure 7 ). In another example, the composite structure 1000 may be used to form the first planar outer layer 624 and the second planar outer layer 625 of the aerosol-generating article 600 (see Figures 9 to 13 ).

[0227] Figure 18BShows yet another embodiment of a composite structure 1000' suitable for use in an aerosol-generating article (such as any one of aerosol-generating articles 100, 200, 300, 400, 500, 600, 700, 800). The composite structure 1000' has a layer 1021 and receptor material particles or strips 1023 (e.g., stainless steel or aluminum particles or strips) applied over the surface of the layer 1021. The layer 1021 is a sheet formed from a paper-based substrate. The paper-based substrate can be a substrate formed from paper or cardboard. An adhesive (not shown) can be used to facilitate the adhesion of the receptor material particles or strips 1023 to the surface of the layer 1021. In an alternative embodiment, an aerosol-forming matrix can be used in place of the paper-based substrate for the layer 1021. Similarly, for example, the composite structure 1000' can be used to form the upper planar layer 310 or the lower planar layer 320 of the aerosol-generating article 300 (see Figure 3 ). In another example, the composite structure 1000' can be used to form the corrugated intermediate layer 340 of the aerosol-generating article 400 (see Figure 7 ). In another example, the composite structure 1000' can be used to form the first planar outer layer 624 and the second planar outer layer 625 of the aerosol-generating article 600 (see Figures 9 to 13 ).

[0228] Figure 18C Shows yet another embodiment of a composite structure 1000'' suitable for use in an aerosol-generating article (such as any one of aerosol-generating articles 100, 200, 300, 400, 500, 600, 700, 800). The composite structure 1000'' has a layer 1031 containing a dispersion of receptor material particles or strips 1033 (e.g., stainless steel or aluminum particles or strips). The layer 1031 is a sheet formed from a paper-based substrate. The paper-based substrate can be a substrate formed from paper or cardboard. In an alternative embodiment, an aerosol-forming matrix can be used in place of the paper-based substrate for the layer 1031. Similarly, for example, the composite structure 1000'' can be used to form the upper planar layer 310 or the lower planar layer 320 of the aerosol-generating article 300 (see Figure 3 ). In another example, the composite structure 1000'' can be used to form the corrugated intermediate layer 340 of the aerosol-generating article 400 (see Figure 7 ). In another example, the composite structure 1000'' can be used to form the first planar outer layer 624 and the second planar outer layer 625 of the aerosol-generating article 600 (see Figures 9 to 13 ).

[0229] Figure 19Shows a composite structure 2000 in the form of a paper-based substrate sheet 2010 (e.g., a paper or cardboard sheet) comprising discrete sensor material sheets 2020a-d (such as aluminum or stainless steel sheets). Each of the sensor material sheets 2020a-d is spaced apart from one another by a distance "a" and defines spatially distinct sensor regions. When used in an aerosol-generating article (such as any one of aerosol-generating articles 100, 200, 300, 400, 500, 600, 700, 800), the composite structure 2000 is preferably arranged such that the discrete sensor material sheets 2020a-d are spaced apart from one another along the airflow path or longitudinal direction (e.g., in the x-direction) of the aerosol-generating article. For example, the composite structure 2000 can be used to form the planar upper layer 310 or the planar lower layer 320 of the aerosol-generating article 300 (see Figure 3 ). In another example, the composite structure 2000 can be used to form the corrugated intermediate layer 340 of the aerosol-generating article 400 (see Figure 7 ). In another example, the composite structure 2000 can be used to form the first planar outer layer 624 and the second planar outer layer 625 of the aerosol-generating article 600 (see Figures 9 to 13 ).

[0230] For the exemplary purpose of being applicable to any one of the above embodiments, the composition of a suitable aerosol-forming substrate can be as follows. Percentages are given as weight percentages relative to the weight of the product in its final state. The aerosol-forming substrate can have about 5% to 25%, preferably about 7% to 15% moisture in the final product state. The aerosol-forming substrate can also comprise the following:

[0231] 1. Tobacco leaves; for example, a tobacco leaf blend of about 15% to 45%, preferably about 20% to 35%, comprising at least one of the following tobacco types: flue-cured tobacco; sun-cured tobacco; oriental tobacco. The tobacco material is ground and sized to a particle size of about 100 to 380 mesh, preferably about 170 to 320 mesh.

[0232] 2. Cellulose fibers; for example, about 1% to 15%, preferably about 3% to 7% cellulose fibers, having a length of about 10 to 250 μm, preferably about 10 to 120 μm.

[0233] 3. Tobacco fibers; for example, about 5% to 20%, preferably about 7% to 15% tobacco fibers of any tobacco type or tobacco type blend, as a filler. The tobacco fibers preferably originate from stems and / or stalks and are sized to fibers having a length of about 10 to 350 μm, preferably about 10 to 180 μm.

[0234] 4. Binder; for example, about 1% to 10%, preferably about 1% to 5% of a binder, such as any of the common gums or pectins used in the food and beverage (F&B) industry. Preferred binders can be natural pectins (such as fruits, e.g., citrus) or tobacco pectin; guar gum, locust bean gum, hydroxyethyl and / or hydroxypropyl derivatives thereof; starches, such as modified or derivatized starches; alginates; methyl, ethyl, ethylhydroxymethyl, and carboxymethyl celluloses; dextran; and xanthan gum. A preferred binder is guar gum.

[0235] 5. Aerosol former; for example, about 5% to 35%, preferably about 10% to 25% of an aerosol former. Suitable aerosol formers known in the art include: glycerol; monohydric alcohols, such as menthol; polyhydric alcohols, such as triethylene glycol; esters of polyhydric alcohols, such as glycerol mono-, di-, or triacetate; and aliphatic esters of mono-, di-, or polycarboxylic acids, such as dimethyl esters thereof.

[0236] "Tobacco type" means one of different tobacco varieties, for example, based on different curing processes that the tobacco undergoes before being further processed into a tobacco product.

[0237] For illustrative purposes, the composition of another aerosol-forming matrix (which may also be suitable for use as the aerosol-forming matrix of any of the above embodiments) is described below. Percentages are given as weight percentages relative to the product in its final state. The aerosol-forming matrix may comprise:

[0238] 1. Aerosol former, such as glycerol; for example, about 10% to 40%, preferably about 20% to 30%.

[0239] 2. Organic fibers; for example, about 10% to 30%, preferably about 15% to 25% of any plant variety that is suitable and of a purity meeting applicable FDA F&B grade requirements, as commonly available on the market. For example, the organic fibers can be derived from cellulose, cotton, wood, tea plant varieties that are by-products and co-processing wastes of the F&B tea industry. The organic fibers preferably have a length of about 10 to 400 μm, preferably about 10 to 200 μm.

[0240] 3. Organic plant glycerol agent; for example, about 15% to 55%, preferably about 20% to 35% of plant materials, such as cloves, Echinacea, fennel, ginger, hawthorn berries, elderberries, Monarda, Verbascum thapsus, nettle, plantain, turmeric, yarrow, and compounds thereof.

[0241] 4. Organic plant extracts; for example, about 1% to 15%, preferably about 2% to 7% of any of the previously mentioned plant materials, and menthol (dl-menthol, C 10 H 20 O, 2-isopropyl-5-methylcyclohexanol) and p-menthan-3-ol, which is any secondary alcohol that is a diastereoisomer of 5-methyl-2-(propan-2-yl)cyclohexan-1-ol.

[0242] Alternatively, such an aerosol-forming substrate may also contain about 0.5% to 5%, preferably about 1% to 3% of essential oils, such as palm essential oil, coconut essential oil, and wood-based essential oil.

[0243] For the purposes of this specification and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, etc. should be understood to be modified in all instances by the term "about". Moreover, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therebetween that may be specifically enumerated or may not be enumerated herein. Thus, in this document, the number "A" is understood to be "A" ± 10% of "A". In this document, the number "A" may be considered to include values within the general standard error of the measurement of the property modified by the number "A". In some cases used in the appended claims, the number "A" may deviate from the percentages listed above, provided that the amount by which "A" deviates does not materially 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 that may be specifically enumerated or may not be enumerated herein. The terms "in which" and "wherein" are used synonymously in this specification.

Claims

1. An aerosol - generating article for use with an aerosol - generating device, the aerosol - generating article comprising a substantially planar upper surface and a substantially planar lower surface, the upper surface and the lower surface being vertically spaced apart from each other by a height defined in the z - direction, the aerosol - generating article further comprising an aerosol - forming substrate and one or more sensor materials, the one or more sensor materials being arranged in thermal communication with the aerosol - forming substrate.

2. The aerosol - generating article according to claim 1, wherein the one or more sensor materials are in direct contact with the aerosol - forming substrate.

3. The aerosol - generating article according to any one of claim 1 or claim 2, wherein the one or more sensor materials are included within the aerosol - forming substrate.

4. The aerosol - generating article according to claim 3, wherein the particles of the sensor material are dispersed within the aerosol - forming substrate.

5. The aerosol - generating article according to any one of claims 1 to 4, wherein the one or more sensor materials are included within the aerosol - generating article as one or more sensor material strips, lines or filaments.

6. The aerosol - generating article according to claim 5, wherein the one or more sensor material strips, lines or filaments are located within the airflow path of the aerosol - generating article.

7. The aerosol - generating article according to any one of claims 1 to 6, wherein the one or more sensor materials are included within the aerosol - generating article as one or more sensor material sheets or layers.

8. The aerosol - generating article according to claim 7, wherein the one or more sensor material sheets or layers are located within the airflow path of the aerosol - generating article or at least partially define the airflow path of the aerosol - generating article.

9. The aerosol - generating article according to any one of claim 7 or claim 8, wherein the one or more sensor material sheets or layers cover an external portion of the aerosol - generating article.

10. The aerosol - generating article according to any one of claims 1 to 9, which comprises a plurality of sensor regions spaced apart from each other and arranged in thermal communication with the aerosol - forming substrate, the plurality of sensor regions comprising or consisting of one or more sensor materials.

11. The aerosol - generating article according to claim 10, wherein the plurality of sensor regions comprise one or more sensor materials overlying or included in a paper - based substrate or the aerosol - forming substrate.

12. The aerosol - generating article according to any one of claims 1 to 11, which further comprises an intermediate layer disposed between an upper layer and a lower layer, the upper surface defining the outer surface of the upper layer, and the lower surface defining the outer surface of the lower layer, wherein the airflow path is defined as passing through the aerosol - generating article between a distal end and a proximal end of the aerosol - generating article in the x / y plane.

13. The aerosol-generating article according to claim 12, wherein at least one of the upper layer, the intermediate layer, and the lower layer comprises or consists of one or more sensor materials.

14. The aerosol-generating article according to any one of claims 1 to 11, further comprising a planar frame positioned between the upper layer and the lower layer, an upper surface defining an outer surface of the upper layer, and a lower surface defining an outer surface of the lower layer, the planar frame defining a cavity, wherein an airflow path is defined to pass through the aerosol-generating article in the x / y plane, the airflow path extending through the cavity.

15. The aerosol-generating article according to claim 14, wherein one or both of the upper layer and the lower layer comprises or consists of one or more sensor materials.

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