Aerosol-generating system with compressible aerosol-generating article

Abstract

An aerosol-generating system comprising an aerosol-generating article (10) comprising: a strip of aerosol-generating substrate (12) and a downstream section (22) downstream of the strip of aerosol-generating substrate (12), and an aerosol-generating device (100) comprising: a body defining a heating chamber (108) (208) (308), the heating chamber is used for removably receiving at least one part of the strip (12) of aerosol-generating substrate when the aerosol-generating article (10) is inserted into the aerosol-generating device (100); and a heater assembly disposed along at least a portion of the heating chamber (108) (208) (308) for heating the strip (12) of aerosol-generating substrate. The heating chamber (108) (208) (308) of the aerosol-generating device (100) has a cross-section configured such that upon insertion of the strip (12) of aerosol-generating substrate into the heating chamber (108) (208) (308), the strip (12) of aerosol-generating substrate is compressed to a final density that is at least 1.5 times the initial density. The strip (12) of aerosol-generating substrate has an initial density of less than 250 mg / cm3.

Description

Technical Field

[0001] The present invention relates to an aerosol generating system comprising an aerosol generating device and a compressible aerosol generating article. Background Art

[0002] Aerosol generating articles in which an aerosol generating substrate such as a tobacco-containing substrate is heated rather than burned are known in the art. Generally, in such heated smoking articles, an aerosol is generated by transferring heat from a heat source to a physically separated aerosol generating substrate or material, which may be positioned in contact with, inside, around or downstream of the heat source. During use of the aerosol generating article, volatile compounds are released from the aerosol generating substrate by heat transfer from the heat source and entrained in the air drawn through the aerosol generating article. When the released compounds cool, the compounds condense to form an aerosol.

[0003] Many prior art documents disclose aerosol generating devices for consuming aerosol generating articles. Such devices include, for example, electrically heated aerosol generating devices, in which an aerosol is generated by transferring heat from one or more electrical heater elements of the aerosol generating device to the aerosol generating substrate of the heated aerosol generating article. For example, an electrically heated aerosol generating device has been proposed that includes internal heater blades adapted to be inserted into the aerosol generating substrate. As an alternative, WO2015 / 176898 proposes an inductively heatable aerosol generating article that includes an aerosol generating substrate and a susceptor disposed within the aerosol generating substrate. Another alternative has been described in WO2020 / 115151, which discloses an aerosol generating article for use in combination with an external heating system that includes one or more heating elements disposed around the perimeter of the aerosol generating article.

[0004] Typically, aerosol generating articles have been produced with a substantially circular cross-section such that the aerosol generating substrate is cylindrical. The device cavity of the corresponding aerosol generating device for heating the aerosol generating article generally has a cylindrical shape and dimensions configured to substantially match the cylindrical shape and dimensions of the aerosol generating substrate such that the aerosol generating substrate can be readily received and retained within the device cavity during heating.

[0005] However, an improved aerosol generating device has been proposed, which has a device chamber with a rectangular cross-section. The device chamber includes opposing planar walls, and at least one of the planar walls is provided with a heater element on its surface. This arrangement provides a potentially larger surface area (on which the aerosol generating substrate can be heated), and significantly improves the heating efficiency of the aerosol generating substrate. It also provides a more compact aerosol generating system that is easier to manufacture. However, consumers may have difficulty using such an aerosol generating device with a conventional cylindrical aerosol generating article, because it may be difficult to sufficiently compress or deform the cylindrical aerosol generating substrate to insert it into the rectangular device chamber. This will be especially the case when the planar walls of the device chamber are relatively close together such that the distance between the planar walls is significantly less than the diameter. Summary of the Invention

[0006] Accordingly, there is a need for an aerosol generating system that includes an aerosol generating device and an aerosol generating article, which is adapted to make the aerosol generating article more compatible with the aerosol generating device even if the aerosol generating article has a different shape from the device chamber of the aerosol generating device.

[0007] According to a first aspect of the present disclosure, an aerosol generating system is provided. The aerosol generating system may include an aerosol generating article for generating an inhalable aerosol upon heating, the aerosol generating article extending from a mouth end to a distal end. The aerosol generating article may include a strip of aerosol generating substrate. The aerosol generating article may include a downstream section located downstream of the strip of aerosol generating substrate, the downstream section extending from the downstream end of the strip of aerosol generating substrate to the mouth end of the aerosol generating article. The aerosol generating system may further include an aerosol generating device. The aerosol generating device may include a body defining a heating chamber for removably receiving at least a portion of the strip of aerosol generating substrate of the aerosol generating article when the aerosol generating article is inserted into the aerosol generating device. The aerosol generating device may include a heater assembly arranged along at least a portion of the heating chamber for heating the strip of aerosol generating substrate when the aerosol generating article is received within the aerosol generating device. The strip of aerosol generating substrate may have an initial density before being inserted into the aerosol generating device. The cross-section of the heating chamber of the aerosol generating device may be configured such that when the strip of aerosol generating substrate is inserted into the heating chamber, the strip of aerosol generating substrate is compressed to a final density. The final density may be at least 1.1 times the initial density.

[0008] According to the present invention, there is provided an aerosol generating system comprising an aerosol generating article and an aerosol generating device. The aerosol generating article is configured to generate an inhalable aerosol upon heating, and extends from a mouth end to a distal end, and comprises: a strip of aerosol generating substrate; and a downstream section located downstream of the strip of aerosol generating substrate, the downstream section extending from the downstream end of the strip of aerosol generating substrate to the mouth end of the aerosol generating article. The aerosol generating device comprises: a body defining a heating chamber configured to removably receive at least a portion of the strip of aerosol generating substrate of the aerosol generating article when the aerosol generating article is inserted into the aerosol generating device; and a heater assembly disposed along at least a portion of the heating chamber for heating the strip of aerosol generating substrate when the aerosol generating article is received within the aerosol generating device. According to the present invention, the strip of aerosol generating substrate has an initial density before the aerosol generating article is inserted into the aerosol generating device, and the cross-sectional configuration of the heating chamber of the aerosol generating device is such that when the strip of aerosol generating substrate is inserted into the heating chamber, the strip of aerosol generating substrate is compressed to a final density which is at least 1.1 times the initial density.

[0009] According to a second aspect of the present disclosure, there is provided an aerosol generating system. The aerosol generating system may comprise an aerosol generating article configured to generate an inhalable aerosol upon heating, the aerosol generating article extending from a mouth end to a distal end. The aerosol generating article may comprise a strip of aerosol generating substrate. The aerosol generating article may comprise a downstream section located downstream of the strip of aerosol generating substrate, the downstream section extending from the downstream end of the strip of aerosol generating substrate to the mouth end of the aerosol generating article. The aerosol generating system may further comprise an aerosol generating device. The aerosol generating device may comprise a body defining a heating chamber configured to removably receive at least a portion of the strip of aerosol generating substrate of the aerosol generating article when the aerosol generating article is inserted into the aerosol generating device. The aerosol generating device may comprise a heater assembly disposed along at least a portion of the heating chamber for heating the strip of aerosol generating substrate when the aerosol generating article is received within the aerosol generating device. The strip of aerosol generating substrate may have an initial cross-sectional area before the aerosol generating article is inserted into the aerosol generating device. The cross-section of the heating chamber of the aerosol generating device may be configured such that when the strip of aerosol generating substrate is inserted into the heating chamber, the strip of aerosol generating substrate is compressed to a final cross-sectional area. The initial cross-sectional area may be at least 1.1 times the final cross-sectional area.

[0010] According to the present invention, there is provided an aerosol generating system, which includes an aerosol generating article and an aerosol generating device. The aerosol generating article is configured to generate an inhalable aerosol upon heating. The aerosol generating article extends from a mouth end to a distal end and includes: a strip of aerosol generating substrate; and a downstream section located downstream of the strip of aerosol generating substrate. The downstream section extends from the downstream end of the strip of aerosol generating substrate to the mouth end of the aerosol generating article. The aerosol generating device includes: a body defining a heating chamber for removably receiving at least a portion of the strip of aerosol generating substrate of the aerosol generating article when the aerosol generating article is inserted into the aerosol generating device; and a heater assembly for heating the strip of aerosol generating substrate when the strip of aerosol generating substrate is received within the heating chamber. According to the present invention, the strip of aerosol generating substrate has an initial cross-sectional area before the aerosol generating article is inserted into the aerosol generating device, and the cross-section of the heating chamber of the aerosol generating device is configured such that when the strip of aerosol generating substrate is inserted into the heating chamber, the strip of aerosol generating substrate is compressed to a final cross-sectional area, where the initial cross-sectional area is at least 1.1 times the final cross-sectional area.

[0011] According to a third aspect of the present disclosure, there is provided an aerosol generating system. The aerosol generating system may include an aerosol generating article configured to generate an inhalable aerosol upon heating. The aerosol generating article extends from a mouth end to a distal end. The aerosol generating article may include a strip of aerosol generating substrate. The aerosol generating article may include a downstream section located downstream of the strip of aerosol generating substrate. The downstream section extends from the downstream end of the strip of aerosol generating substrate to the mouth end of the aerosol generating article. The aerosol generating system may further include an aerosol generating device. The aerosol generating device may include a body defining a heating chamber for removably receiving at least a portion of the strip of aerosol generating substrate of the aerosol generating article when the aerosol generating article is inserted into the aerosol generating device. The aerosol generating device may include a heater assembly disposed along at least a portion of the heating chamber for heating the strip of aerosol generating substrate when the aerosol generating article is received within the aerosol generating device. The strip of aerosol generating substrate may have an initial maximum diameter before the aerosol generating article is inserted into the aerosol generating device. The cross-section of the heating chamber of the aerosol generating device may be configured such that when the strip of aerosol generating substrate is inserted into the heating chamber, the strip of aerosol generating substrate is compressed to a final maximum diameter. The final maximum diameter after compression may be at least 1.1 times the initial maximum diameter.

[0012] According to the present invention, there is provided an aerosol generating system including an aerosol generating article and an aerosol generating device. The aerosol generating article is configured to generate an inhalable aerosol upon heating, extends from a mouth end to a distal end, and includes: a strip of aerosol generating substrate; and a downstream section located downstream of the strip of aerosol generating substrate, the downstream section extending from a downstream end of the strip of aerosol generating substrate to the mouth end of the aerosol generating article. The aerosol generating device includes: a body defining a heating chamber for removably receiving at least a portion of the strip of aerosol generating substrate of the aerosol generating article when the aerosol generating article is inserted into the aerosol generating device; and a heater assembly for heating the strip of aerosol generating substrate when the strip of aerosol generating substrate is received within the heating chamber. Wherein the strip of aerosol generating substrate has an initial maximum diameter prior to the aerosol generating article being inserted into the aerosol generating device, and wherein a cross-section of the heating chamber of the aerosol generating device is configured such that when the strip of aerosol generating substrate is inserted into the heating chamber, the strip of aerosol generating substrate is compressed such that the strip of aerosol generating substrate has a final maximum diameter after compression, the final maximum diameter being at least 1.1 times the initial maximum diameter.

[0013] As used herein, the term "aerosol generating article" refers to an article including an aerosol generating substrate that is heated to generate an inhalable aerosol and deliver the inhalable aerosol to a consumer. As used herein, the term "aerosol generating substrate" denotes a substrate capable of releasing volatile compounds upon heating to generate an aerosol.

[0014] As used herein, the term "aerosol generating device" refers to a device including a heater element that interacts with an aerosol generating substrate of an aerosol generating article to generate an aerosol.

[0015] As used herein in reference to the present invention, the term "strip" is used to denote a generally elongated element, preferably a cylindrical element, having a substantially circular, oval, or elliptical cross-section.

[0016] As used herein, the term "longitudinal" refers to a 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. As used herein, the terms "upstream" and "downstream" describe the relative positions of elements or portions of elements of the aerosol generating article with respect to the direction in which aerosol is delivered through the aerosol generating article during use.

[0017] During use, air is drawn through the aerosol-generating article in a "longitudinal" direction. The term "transverse" refers to a direction perpendicular to the longitudinal axis. Unless otherwise specified, any reference to a "cross-section" of the aerosol-generating article or a component of the aerosol-generating article refers to a cross-section.

[0018] The term "length" denotes the dimension of a component of the aerosol-generating article in the longitudinal direction. For example, it can be used to denote the dimension of a bar or a downstream section in the longitudinal direction.

[0019] As used herein, the term "density" in relation to the aerosol-generating substrate refers to the volume density of the aerosol-generating substrate. This can be calculated by measuring the total weight of the aerosol-generating substrate and dividing it by the volume of the segment of the aerosol-generating substrate (excluding any packaging). The initial density of the aerosol-generating substrate refers to the density of the aerosol-generating substrate before it is inserted into the aerosol-generating device. The final density of the aerosol-generating substrate refers to the density of the aerosol-generating substrate once it has been placed inside the aerosol-generating device.

[0020] In all aspects of the present invention, the aerosol-generating system includes an aerosol-generating article that is adapted to allow the aerosol-generating substrate to be compressible. The heating chamber is configured to have a specific size and shape relative to the aerosol-generating substrate such that, before heating, during insertion of the aerosol-generating article into the aerosol-generating device by the consumer, the aerosol-generating substrate of the aerosol-generating article is compressed. This compression of the aerosol-generating substrate causes a change in the shape and form of the aerosol-generating substrate.

[0021] Accordingly, the aerosol-generating system of the present invention provides a novel combination of an aerosol-generating device and an aerosol-generating article, wherein when the aerosol-generating article is inserted into the aerosol-generating device, the initial form of the aerosol-generating substrate is adjusted to improve the efficiency of heating the aerosol-generating substrate during use. In particular, when the aerosol-generating substrate is inserted into the heating chamber of the aerosol-generating device, the compression or flattening of the aerosol-generating substrate reduces at least one dimension of the aerosol-generating substrate such that heat can be transferred more effectively through the aerosol-generating substrate and the release of active ingredients from the aerosol-generating substrate can be maximized.

[0022] In the aerosol-generating system of the present invention, despite the difference in shape between the aerosol-generating article and the heating chamber, the adaptation of the aerosol-generating article makes it compressible such that it can be inserted into a "flat" heater having a heating chamber with a flat heating surface as described below. Thus, even in the case of a cylindrical article, the benefits of using a "flat" heater can be obtained in terms of more efficient heating.

[0023] Advantageously, the remainder of the aerosol - generating article that is not inserted into the aerosol - generating device does not need to be compressed, and thus the properties and functions of the downstream section of the aerosol - generating article will be largely or completely unaffected.

[0024] In the aerosol - generating system according to the first aspect of the present invention, the aerosol - generating article and the heating chamber of the aerosol - generating device are adapted such that when inserted into the aerosol - generating device, the aerosol - generating substrate is compressed and the density of the aerosol - generating substrate increases by at least 1.1 times from an initial density to a final density. Thus, the ratio of the final density to the initial density, obtained by dividing the final density by the initial density, is at least 1.1. Preferably, the initial density of the aerosol - generating substrate is relatively low such that the aerosol - generating substrate can be compressed enough to be inserted into the heating chamber of the aerosol - generating device.

[0025] Preferably, the initial density of the aerosol - generating substrate is less than 300 mg / cubic centimeter, more preferably less than 275 mg / cubic centimeter, more preferably less than 250 mg / cubic centimeter, more preferably less than 225 mg / cubic centimeter, more preferably less than 200 mg / cubic centimeter, more preferably less than 175 mg / cubic centimeter, more preferably less than 150 mg / cubic centimeter, more preferably less than 125 mg / cubic centimeter.

[0026] Preferably, the initial density is at least 75 mg / cubic centimeter, more preferably at least 80 mg / cubic centimeter, more preferably at least 85 mg / cubic centimeter, more preferably at least 90 mg / cubic centimeter, more preferably at least 95 mg / cubic centimeter, more preferably at least 100 mg / cubic centimeter, more preferably at least 105 mg / cubic centimeter, more preferably at least 110 mg / cubic centimeter.

[0027] For example, the initial density can be between 75 mg / cubic centimeter and 300 mg / cubic centimeter, or between 80 mg / cubic centimeter and 275 mg / cubic centimeter, between 85 mg / cubic centimeter and 250 mg / cubic centimeter, or between 90 mg / cubic centimeter and 225 mg / cubic centimeter, or between 95 mg / cubic centimeter and 200 mg / cubic centimeter, or between 100 mg / cubic centimeter and 175 mg / cubic centimeter, or between 105 mg / cubic centimeter and 150 mg / cubic centimeter, or between 110 mg / cubic centimeter and 125 mg / cubic centimeter.

[0028] The final density of the aerosol - generating substrate after it has been inserted into the heating chamber of the aerosol - generating device will depend on the initial density and the degree to which the aerosol - generating substrate is compressed when inserted into the aerosol - generating device. According to the present invention, the final density is at least 1.1 times the initial density. Preferably, the final density is at least 1.25 times the initial density, more preferably at least 1.5 times the initial density, more preferably at least 1.75 times the initial density, and more preferably twice the initial density. The final density can be up to 4 times the initial density, or up to 3 times the initial density.

[0029] For example, the final density can be between 1.1 times and 4 times the initial density, or between 1.25 times and 4 times the initial density, or between 1.5 times and 4 times the initial density, or between 1.75 and 4 times the initial density, or between 2 times and 4 times the initial density, or between 1.1 times and 3 times the initial density, or between 1.25 times and 3 times the initial density, or between 1.5 times and 3 times the initial density, or between 1.75 times and 3 times the initial density, or between 2 times and 3 times the initial density.

[0030] Preferably, the final density is at least 150 mg / cubic centimeter, more preferably at least 175 mg / cubic centimeter, more preferably at least 200 mg / cubic centimeter, more preferably at least 225 mg / cubic centimeter, more preferably at least 250 mg / cubic centimeter, more preferably at least 275 mg / cubic centimeter, more preferably at least 300 mg / cubic centimeter.

[0031] Preferably, the final density of the aerosol - generating substrate is less than 500 mg / cubic centimeter, more preferably less than 475 mg / cubic centimeter, more preferably less than 450 mg / cubic centimeter, more preferably less than 425 mg / cubic centimeter, more preferably less than 400 mg / cubic centimeter, more preferably less than 375 mg / cubic centimeter, more preferably less than 350 mg / cubic centimeter.

[0032] For example, the final density can be between 150 mg / cubic centimeter and 500 mg / cubic centimeter, or between 175 mg / cubic centimeter and 475 mg / cubic centimeter, between 200 mg / cubic centimeter and 450 mg / cubic centimeter, or between 225 mg / cubic centimeter and 425 mg / cubic centimeter, or between 250 mg / cubic centimeter and 400 mg / cubic centimeter, or between 275 mg / cubic centimeter and 375 mg / cubic centimeter, or between 300 mg / cubic centimeter and 350 mg / cubic centimeter.

[0033] Alternatively or additionally, the heating chamber of the aerosol-generating article and the aerosol-generating device is adapted such that when inserted into the aerosol-generating device, the aerosol-generating substrate deforms and changes shape such that the cross-sectional area of the aerosol-generating substrate is reduced, wherein the initial cross-sectional area is at least 1.1 times the final cross-sectional area.

[0034] The cross-sectional area of a strip of the aerosol-generating substrate refers to the area of a cross-section taken through the strip of the aerosol-generating substrate in a direction transverse or perpendicular to the longitudinal axis of the strip of the aerosol-generating substrate, the longitudinal axis extending along the length of the elongate strip as defined above. In cases where the cross-sectional area varies along the length of the strip of the aerosol-generating substrate, the average cross-sectional area should be considered.

[0035] In many preferred embodiments, when the aerosol-generating article is inserted into the heating chamber of the aerosol-generating device, a reduction in cross-sectional area will occur as the strip of the aerosol-generating substrate deforms from a substantially circular cross-section towards a more oval or rectangular cross-section. Thus, inserting the aerosol-generating article into the heating chamber generally causes an overall flattening of the strip of the aerosol-generating substrate in one direction. This flattening will improve heat transfer through the strip of the aerosol-generating substrate during heating and thereby improve the efficiency of aerosol generation from the aerosol-generating substrate.

[0036] The initial cross-sectional area of the strip of the aerosol-generating substrate is preferably at least 28 square millimeters, more preferably at least 30 square millimeters, more preferably at least 32 square millimeters, more preferably at least 34 square millimeters, more preferably at least 36 square millimeters.

[0037] The initial cross-sectional area of the strip of the aerosol-generating substrate is preferably less than 50 square millimeters, more preferably less than 48 square millimeters, more preferably less than 46 square millimeters, more preferably less than 44 square millimeters, more preferably less than 42 square millimeters.

[0038] For example, the initial cross-sectional area of the strip of the aerosol-generating substrate can be between 28 square millimeters and 50 square millimeters, or between 30 square millimeters and 48 square millimeters, or between 32 square millimeters and 46 square millimeters, or between 34 square millimeters and 44 square millimeters, or between 36 square millimeters and 42 square millimeters.

[0039] The final cross-sectional area of the strip of the aerosol-generating substrate after it has been inserted into the heating chamber of the aerosol-generating device will depend on the initial cross-sectional area and the degree to which the strip of the aerosol-generating substrate is compressed or deformed when inserted into the aerosol-generating device.

[0040] According to the present invention, the initial cross-sectional area is at least 1.1 times the final cross-sectional area. Preferably, the initial cross-sectional area is at least 1.25 times the final cross-sectional area, more preferably at least 1.5 times the final cross-sectional area, more preferably at least 1.75 times the final cross-sectional area, and even more preferably at least twice the final cross-sectional area. The initial cross-sectional area can be up to 4 times the final cross-sectional area, or up to 3 times the final cross-sectional area.

[0041] For example, the initial cross-sectional area can be between 1.1 times and 4 times the final cross-sectional area, or between 1.25 times and 4 times the final cross-sectional area, or between 1.5 times and 4 times the final cross-sectional area, or between 1.75 times and 4 times the final cross-sectional area, or between 2 times and 4 times the final cross-sectional area, or between 1.1 times and 3 times the final cross-sectional area, or between 1.25 times and 3 times the final cross-sectional area, or between 1.5 times and 3 times the final cross-sectional area, or between 1.75 times and 3 times the final cross-sectional area, or between 2 times and 3 times the final cross-sectional area.

[0042] Preferably, the final cross-sectional area is less than 30 square millimeters, more preferably less than 28 square millimeters, more preferably less than 26 square millimeters, more preferably less than 24 square millimeters, and even more preferably less than 22 square millimeters.

[0043] Preferably, the final cross-sectional area is at least 10 square millimeters, more preferably at least 12 square millimeters, more preferably at least 14 square millimeters, more preferably at least 16 square millimeters, and even more preferably at least 18 square millimeters.

[0044] For example, the final cross-sectional area can be between 10 square millimeters and 30 square millimeters, or between 12 square millimeters and 28 square millimeters, or between 14 square millimeters and 26 square millimeters, or between 16 square millimeters and 24 square millimeters, or between 18 square millimeters and 22 square millimeters.

[0045] Alternatively or additionally, the heating chamber of the aerosol-generating article and the aerosol-generating device is adapted such that when inserted into the aerosol-generating device, the aerosol-generating substrate is compressed, such that the maximum diameter of the strip of the aerosol-generating substrate increases, wherein the final maximum diameter is at least 1.1 times the initial maximum diameter.

[0046] The maximum diameter of the strip of the aerosol-generating substrate refers to the maximum external dimension of the strip of the aerosol-generating substrate in a plane transverse or perpendicular to the longitudinal axis of the strip of the aerosol-generating substrate. In other words, the maximum diameter corresponds to the maximum external dimension of the cross-section of the strip of the aerosol-generating substrate. In the case where the cross-section varies along the length of the strip of the aerosol-generating substrate, the average maximum diameter should be considered. In the case where the strip of the aerosol-generating substrate has a substantially circular cross-section, the maximum diameter will correspond to the overall diameter of the circle.

[0047] In many preferred embodiments, when the aerosol - forming article is inserted into the heating chamber of the aerosol - generating device, the compression of the strip of the aerosol - forming substrate will cause the strip of the aerosol - forming substrate to deform from a substantially circular cross - section towards a more oval or rectangular cross - section. Thus, inserting the aerosol - forming article into the heating chamber generally causes an overall flattening of the strip of the aerosol - forming substrate in one direction and a corresponding increase in the maximum diameter. This flattening will improve heat transfer through the strip of the aerosol - forming substrate during heating and, thereby, improve the efficiency of aerosol generation from the aerosol - forming substrate.

[0048] Preferably, before the aerosol - forming article is inserted into the aerosol - generating device, the initial maximum diameter of the strip of the aerosol - forming substrate is at least 6 mm, more preferably at least 6.25 mm, more preferably at least 6.5 mm, more preferably at least 6.75 mm, more preferably at least 7 mm.

[0049] Preferably, before the aerosol - forming article is inserted into the aerosol - generating device, the initial maximum diameter of the strip of the aerosol - forming substrate is less than 8.5 mm, more preferably less than 8.25 mm, more preferably less than 8 mm, more preferably less than 7.75 mm, more preferably less than 7.5 mm.

[0050] For example, the initial maximum diameter can be between 6 mm and 8.5 mm, or between 6.25 mm and 8.25 mm, or between 6.5 mm and 8 mm, or between 6.75 mm and 7.75 mm, or between 7 mm and 7.5 mm. The initial maximum diameter can be about 7.1 mm.

[0051] The final maximum diameter of the strip of the aerosol - forming substrate after it has been inserted into the heating chamber of the aerosol - generating device will depend on the initial maximum diameter and the degree to which the strip of the aerosol - forming substrate is compressed when inserted into the aerosol - generating device. According to the present invention, the final maximum diameter is at least 1.1 times the initial maximum diameter. Preferably, the final maximum diameter is at least 1.15 times the initial maximum diameter, more preferably at least 1.2 times the initial maximum diameter, more preferably at least 1.25 times the initial maximum diameter. The final maximum diameter can be up to 3 times the initial maximum diameter, or up to 2 times the initial maximum diameter.

[0052] For example, the final maximum diameter can be between 1.1 times and 3 times the initial maximum diameter, or between 1.15 times and 3 times the initial maximum diameter, or between 1.2 times and 3 times the initial maximum diameter, or between 1.25 and 3 times the initial maximum diameter, or between 1.1 times and 2 times the initial maximum diameter, or between 1.15 times and 2 times the initial maximum diameter, or between 1.2 times and 2 times the initial maximum diameter, or between 1.25 and 2 times the initial maximum diameter.

[0053] Preferably, after the aerosol - generating article is inserted into the aerosol - generating device, the final maximum diameter of the strip of the aerosol - generating substrate is at least 8 mm, more preferably at least 8.25 mm, more preferably at least 8.5 mm, more preferably at least 8.75 mm, and more preferably at least 9 mm.

[0054] Preferably, after the aerosol - generating article is inserted into the aerosol - generating device, the final maximum diameter of the strip of the aerosol - generating substrate is less than 10.5 mm, more preferably less than 10.25 mm, more preferably less than 10 mm, more preferably less than 9.75 mm, and more preferably less than 9.5 mm.

[0055] For example, the final maximum diameter can be between 8 mm and 10.5 mm, or between 8.25 mm and 10.25 mm, or between 8.5 mm and 10 mm, or between 8.75 mm and 9.75 mm, or between 9 mm and 9.5 mm. The final maximum diameter can be about 9.2 mm.

[0056] As described above, in all aspects of the present invention, inserting the aerosol - generating article into the aerosol - generating device preferably causes an overall flattening of the strip of the aerosol - generating substrate. Preferably, the strip of the aerosol - generating substrate has a substantially circular cross - section before the aerosol - generating article is inserted into the aerosol - generating device. After the aerosol - generating article is inserted into the aerosol - generating device, the strip of the aerosol - generating substrate preferably has a substantially rectangular cross - section. Alternatively, after the aerosol - generating article is inserted into the aerosol - generating device, the strip of the aerosol - generating substrate can have a substantially oval cross - section.

[0057] In the case where the strip of the aerosol - generating substrate has a substantially rectangular cross - section after the aerosol - generating article is inserted into the aerosol - generating device, the width of the rectangle is preferably at least twice the height of the rectangle, more preferably at least 3 times the height, and more preferably at least 4 times the height. The width and height of the rectangle are measured perpendicular to each other, where the width of the rectangle corresponds to the longer of the two dimensions. Thus, the width corresponds to the maximum diameter of the cross - section of the strip of the aerosol - generating substrate and preferably has a value within the range defined above for the final maximum diameter of the strip of the aerosol - generating substrate. The height of the rectangle is preferably between 1 mm and 4 mm, or between 1.5 mm and 3.5 mm, or between 2 mm and 3 mm.

[0058] As described above, inserting the aerosol - generating article into the aerosol - generating device can cause some compression and deformation of the aerosol - generating substrate. This compression can affect the draw resistance (RTD) of the strip of the aerosol - generating substrate, and the aerosol - generating article should be adapted such that the draw resistance of the aerosol - generating article after insertion into the aerosol - generating device is within an acceptable range as defined below.

[0059] Unless otherwise stated, the draw resistance (RTD) of the component or the aerosol-generating article is measured according to ISO 6565-2015. The RTD refers to the pressure required to force air through the full length of the component. The term "pressure drop" or "draw resistance" of the component or article may also refer to "resistance to draw". Such terms generally refer to measurements according to ISO 6565-2015. Generally in tests, the measurements are carried out at a temperature of 22 °C, a pressure of 101 kPa (about 760 Torr) and a relative humidity of 60% at the output or downstream end of the component at a volumetric flow rate of 17.5 ml / s. The conditions for smoking and the specifications of the smoking machine are set out in ISO standard 3308 (ISO 3308:2000). The atmosphere for conditioning and testing is set out in ISO standard 3402 (ISO 3402:1999).

[0060] After the aerosol-generating article is inserted into the aerosol-generating device, the RTD of the strip of the aerosol-generating substrate is preferably less than or equal to 10 mm H2O, more preferably less than or equal to 9 mm H2O, and even more preferably less than or equal to 8 mm H2O.

[0061] After the aerosol-generating article is inserted into the aerosol-generating device, the RTD of the strip of the aerosol-generating substrate is preferably at least 4 mm H2O, more preferably at least 5 mm H2O, and even more preferably at least 6 mm H2O.

[0062] For example, after the aerosol-generating article is inserted into the aerosol-generating device, the RTD of the strip of the aerosol-generating substrate can be 4 mm H2O to 10 mm H2O, or 5 mm H2O to 10 mm H2O, or 6 mm H2O to 10 mm H2O, or 4 mm H2O to 9 mm H2O, or 5 mm H2O to 9 mm H2O, or 6 mm H2O to 9 mm H2O, or 4 mm H2O to 8 mm H2O, or 5 mm H2O to 8 mm H2O, or 6 mm H2O to 8 mm H2O.

[0063] Preferably, the strip of the aerosol-generating substrate has a length of at least 8 mm, more preferably at least 9 mm, and even more preferably at least 10 mm. Preferably, the length of the strip of the aerosol-generating substrate is less than 16 mm, more preferably less than 15 mm, and even more preferably less than 14 mm. For example, the strip of the aerosol-generating substrate can have a length between 8 mm and 16 mm, or between 9 mm and 15 mm, or between 10 mm and 14 mm. In a particularly preferred embodiment, the strip of the aerosol-generating substrate has a length of about 12 mm.

[0064] Preferably, the ratio between the length of the strip of aerosol - forming substrate and the overall length of the aerosol - generating article is at least 0.10, more preferably at least 0.15, more preferably at least 0.20, more preferably at least 0.25. Preferably, the ratio between the length of the strip of aerosol - forming substrate and the overall length of the aerosol - generating article is less than 0.50, more preferably less than 0.45, more preferably less than 0.40, more preferably less than 0.35. For example, the ratio between the length of the strip of aerosol - forming substrate and the overall length of the aerosol - generating article may be between 0.1 and 0.5, or between 0.15 and 0.45, or between 0.2 and 0.4, or between 0.25 and 0.35.

[0065] Before the aerosol - generating article is inserted into the aerosol - generating device, the strip of aerosol - forming substrate preferably has an outer diameter that is substantially equal to the outer diameter of the aerosol - generating article.

[0066] Preferably, before the aerosol - generating article is inserted into the aerosol - generating device, the strip of aerosol - forming substrate has an outer diameter of at least 5 mm, more preferably at least 6 mm, more preferably at least 7 mm. Before the aerosol - generating article is inserted into the aerosol - generating device, the strip of aerosol - forming substrate preferably has an outer diameter of less than 12 mm, more preferably less than 10 mm, more preferably less than 8 mm. For example, the outer diameter may be between 5 mm and 12 mm, or between 6 mm and 10 mm, or between 7 mm and 8 mm. In a particularly preferred embodiment, the strip of aerosol - forming substrate has an outer diameter of approximately 7.1 mm.

[0067] Preferably, the strip of aerosol - forming substrate has a substantially uniform cross - section along the length of the strip. Particularly preferably, before the aerosol - generating article is inserted into the aerosol - generating device, the strip of aerosol - forming substrate has a substantially circular cross - section.

[0068] The aerosol - forming substrate may be a solid aerosol - forming substrate. Suitable types of materials for use in the aerosol - forming substrate are described below and include, for example, tobacco cut - filler, homogenized tobacco materials such as cast leaves, aerosol - forming films, and gel compositions.

[0069] Preferably, the aerosol - forming substrate contains an aerosol - forming agent. The aerosol - forming agent may be any suitable known compound or mixture of compounds that aids in the formation of a dense and stable aerosol during use. The aerosol - forming agent may facilitate the substantially heat - resistant degradation of the aerosol at the temperatures typically applied during the use of the aerosol - generating article. Suitable aerosol - forming agents are, for example: polyols such as triethylene glycol, 1,3 - butanediol, propylene glycol, and glycerol; esters of polyols such as glycerol mono -, di - or tri - acetate; aliphatic esters of monocarboxylic, dicarboxylic or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate; and combinations thereof.

[0070] Preferably, the aerosol - forming agent comprises one or more of glycerol and propylene glycol. The aerosol - forming agent may consist of glycerol or propylene glycol or a combination of glycerol and propylene glycol.

[0071] In certain embodiments, the aerosol - generating substrate preferably comprises at least 5 wt% of the aerosol - forming agent, more preferably at least 10 wt% of the aerosol - forming agent, and even more preferably at least 15 wt% of the aerosol - forming agent, based on the dry weight of the aerosol - generating substrate. In such embodiments, the aerosol - generating substrate preferably comprises no more than 30 wt% of the aerosol - forming agent, more preferably no more than 25 wt% of the aerosol - forming agent, and even more preferably no more than 20 wt% of the aerosol - forming agent, based on the dry weight. For example, the content of the aerosol - forming agent in the aerosol - generating substrate may be between 5 wt% and 30 wt%, or between 10 wt% and 25 wt%, or between about 15 wt% and about 20 wt%, based on the dry weight. In such embodiments, the content of the aerosol - forming agent is thus relatively low.

[0072] In other embodiments, the aerosol - generating substrate preferably comprises at least 40 wt% of the aerosol - forming agent, more preferably at least 45 wt% of the aerosol - forming agent, and even more preferably at least 50 wt% of the aerosol - forming agent, based on the dry weight of the aerosol - generating substrate. In such embodiments, the aerosol - generating substrate preferably comprises no more than 80 wt% of the aerosol - forming agent, more preferably no more than 75 wt% of the aerosol - forming agent, and even more preferably no more than 70 wt% of the aerosol - forming agent, based on the dry weight. For example, the content of the aerosol - forming agent in the aerosol - generating substrate may be between 40 wt% and 80 wt%, or between 45 wt% and 75 wt%, or between about 50 wt% and about 70 wt%, based on the dry weight. In such embodiments, the content of the aerosol - forming agent is thus relatively high.

[0073] In some preferred embodiments, the aerosol - generating substrate comprises tobacco material. For example, the aerosol - generating substrate may comprise shredded tobacco material. For example, as described in more detail below, the shredded tobacco material may be in the form of cut - filler. Alternatively, the shredded tobacco material may be in the form of pieces of homogenized tobacco material. Suitable homogenized tobacco materials for use in the present invention are described below.

[0074] In the context of this specification, the term "cut - filler" is used to describe a blend of shredded plant material, such as tobacco plant material, and particularly includes one or more of leaves, processed stems and ribs, and homogenized plant material.

[0075] The cut - filler may also include other post - cut filler tobaccos or flavorings.

[0076] Preferably, the shredded filler comprises at least 25% of plant leaves, more preferably at least 50% of plant leaves, still more preferably at least 75% of plant leaves, and most preferably at least 90% of plant leaves. Preferably, the plant material is one of tobacco, mint, tea, and clove. Most preferably, the plant material is tobacco. However, the present invention is equally applicable to other plant materials having the ability to release substances upon application of heat and subsequently form an aerosol.

[0077] The shredded filler suitable for use with the present invention may generally be similar to the shredded filler used in conventional smoking articles. The shred width of the shredded filler may preferably be between 0.3 mm and 2.0 mm, or between 0.5 mm and 1.2 mm, or between 0.6 mm and 0.9 mm.

[0078] Preferably, the strands have a length between about 10 mm and about 40 mm before being assembled into a strip of aerosol - forming substrate.

[0079] In a preferred embodiment, the weight of the shredded filler is between 25 mg and 150 mg, preferably between 30 mg and 125 mg, more preferably between 40 mg and 100 mg. This amount of shredded filler generally allows for sufficient material to form an aerosol during early puffing.

[0080] Preferably, the shredded filler is soaked with an aerosol - forming agent. Soaking the shredded filler can be accomplished by spraying or by other suitable application methods. The aerosol - forming agent can be applied to the blend during the preparation of the shredded filler. For example, the aerosol - forming agent can be applied to the blend in a direct conditioning casing cylinder (DCCC). Conventional machines can be used to apply the aerosol - forming agent to the shredded filler. Suitable aerosol - forming agents are set forth above.

[0081] Preferably, the aerosol - forming agent in the shredded filler comprises one or more of glycerol and propylene glycol. The aerosol - forming agent can consist of glycerol or propylene glycol or a combination of glycerol and propylene glycol.

[0082] In other preferred embodiments, the aerosol - forming substrate comprises homogenized plant material, preferably homogenized tobacco material.

[0083] As used herein, the term "homogenized plant material" includes any plant material formed by the coalescence of plant particles. For example, a sheet or web of homogenized tobacco material for use in the aerosol - generating substrate of the present invention can be formed by coalescing particles of tobacco material, which particles are obtained by comminuting, grinding, or crushing plant material and optionally one or more of tobacco leaves and tobacco stems. The homogenized plant material can be produced by casting, extrusion, papermaking processes, or any other suitable process known in the art.

[0084] The homogenized plant material can be provided in any suitable form.

[0085] In some embodiments, the homogenized plant material can be in the form of one or more sheets. As used herein with reference to the present invention, the term "sheet" describes a layered element having a width and length that are substantially greater than its thickness.

[0086] The homogenized plant material can be in the form of a plurality of pellets or microparticles.

[0087] The homogenized plant material can be in the form of a plurality of strands, ribbons, or fragments. As used herein, the term "strand" describes an elongate element of material having a length that is significantly greater than its width and thickness. The term "strand" should be considered to include ribbons, fragments, and any other homogenized plant material having a similar form. Strands of homogenized plant material can be formed from sheets of homogenized plant material, for example by cutting or shredding, or by other methods, such as by extrusion methods.

[0088] The aerosol - forming agent content of the homogenized tobacco material is preferably within the range defined above for an aerosol - generating substrate having a relatively low aerosol - forming agent content.

[0089] In other preferred embodiments, the aerosol - generating substrate is in the form of an aerosol - generating film comprising a cellulose - based film - forming agent, nicotine, and an aerosol - forming agent. The aerosol - generating film can also include a cellulose - based reinforcing agent. The aerosol - generating film can also include water, preferably 30 wt% or less water.

[0090] As used herein, the term "film" is used to describe a solid, layered element having a thickness that is less than its width or length. The film can be self - supporting. In other words, the film can have cohesive and mechanical properties such that the film can be separated from the support surface even if obtained by casting a film formulation on the support surface. Alternatively, the film can be disposed on a support or sandwiched between other materials. This can enhance the mechanical stability of the film.

[0091] The aerosol - forming agent content of the aerosol - generating film is within the range defined above for an aerosol - generating substrate having a relatively high aerosol - forming agent content.

[0092] In the context of the present invention, the term "cellulose-based film former" is used to describe a cellulose polymer capable of forming a continuous film alone or in the presence of an auxiliary thickener. Preferably, the cellulose-based film former is selected from hydroxypropyl methylcellulose (HPMC), methylcellulose (MC), ethylcellulose (EC), hydroxyethyl methylcellulose (HEMC), hydroxyethylcellulose (HEC), hydroxypropylcellulose (HPC), and combinations thereof. In a particularly preferred embodiment, the cellulose-based film former is HPMC.

[0093] The aerosol-generating film has a cellulose-based film former content, by dry weight, between 10 wt% and 40 wt%, or between 15 wt% and 35 wt%, or between 20 wt% and 30 wt%.

[0094] Preferably, the aerosol-generating film further comprises a cellulose-based reinforcing agent. Preferably, the cellulose-based reinforcing agent is selected from cellulose fibers, microcrystalline cellulose (MCC), cellulose powder, and combinations thereof.

[0095] The aerosol-generating film may have a cellulose-based reinforcing agent content, by dry weight, between 0.5 wt% and 40 wt%, or by dry weight between 5 wt% and 30 wt%, or by dry weight between 10 wt% and 25 wt%.

[0096] The aerosol-generating film may further comprise carboxymethylcellulose, preferably sodium carboxymethylcellulose. The aerosol-generating film may have a carboxymethylcellulose content, by dry weight, between 1 wt% and 15 wt%, or between 2 wt% and 12 wt%, or between 4 wt% and 10 wt%.

[0097] The aerosol-generating film preferably contains nicotine. As used herein with respect to the present invention, the term "nicotine" is used to describe nicotine, nicotine base, or nicotine salts. In embodiments where the aerosol-generating film contains nicotine base or nicotine salts, the amounts of nicotine recited herein are the amounts of free base nicotine or protonated nicotine, respectively.

[0098] The aerosol-generating film may contain natural nicotine or synthetic nicotine.

[0099] The aerosol-generating film may contain one or more monovalent nicotine salts. As used herein with respect to the present invention, the term "monovalent nicotine salt" is used to describe a nicotine salt of a monobasic acid.

[0100] Preferably, the aerosol-generating film contains nicotine, by dry weight, between 0.5 wt% and 10 wt%, or between 1 wt% and 8 wt%, or between 2 wt% and 6 wt%.

[0101] The aerosol-generating film may be a substantially tobacco-free aerosol-generating film.

[0102] In a preferred embodiment, the aerosol-forming film comprises an acid. More preferably, the aerosol-forming film comprises one or more organic acids. Even more preferably, the aerosol-forming film comprises one or more carboxylic acids. In a particularly preferred embodiment, the acid is lactic acid, benzoic acid, fumaric acid or levulinic acid.

[0103] Preferably, the aerosol-forming film comprises an acid in an amount between 0.25% and 3.5% by weight, or between 0.5% and 3% by weight, or between 1% and 2.5% by weight, based on dry weight.

[0104] The aerosol-forming film may have a thickness of from about 0.1 mm to about 1 mm, more preferably from about 0.1 mm to about 0.75 mm, even more preferably from about 0.1 mm to about 0.5 mm. In a particularly preferred embodiment, a layer of the film-forming composition is formed having a thickness of from about 50 microns to 400 microns, more preferably from about 100 microns to 200 microns.

[0105] Optionally, the aerosol-forming film may be disposed on a suitable carrier element within the aerosol-forming segment.

[0106] In an alternative embodiment of the present invention, the aerosol-forming substrate may comprise a gel composition comprising nicotine, at least one gelling agent and an aerosol former. The gel composition is preferably substantially tobacco-free.

[0107] The preferred weight ranges of nicotine in the gel composition are the same as those defined above for the aerosol-forming film.

[0108] The gel composition preferably comprises at least 50% by weight, more preferably at least 60% by weight, even more preferably at least 70% by weight, of an aerosol former, based on dry weight. The gel composition may contain up to 80% by weight of an aerosol former. The aerosol former in the gel composition is preferably glycerol.

[0109] The gel composition preferably comprises at least one gelling agent. Preferably, the total amount of gelling agent comprised in the gel composition is in the range of from about 0.4% to about 10% by weight, or from about 0.5% to about 8% by weight, or from about 1% to about 6% by weight, or from about 2% to about 4% by weight, or from about 2% to about 3% by weight.

[0110] The term "gelling agent" refers to a compound that, when added in an amount of about 0.3% by weight to a 50% water / 50% glycerol mixture, homogeneously forms a solid medium or support matrix that produces a gel. Gelling agents include, but are not limited to, hydrogen bond crosslinking gelling agents and ionic crosslinking gelling agents.

[0111] The term "hydrogen bond cross-linked gelling agent" refers to a gelling agent that forms non-covalent cross-links or physical cross-links via hydrogen bonds. The hydrogen bond cross-linked gelling agent may include one or more of galactomannan, gelatin, agarose, konjac gum, or agar. The hydrogen bond cross-linked gelling agent may preferably include agar.

[0112] The term "ionic cross-linked gelling agent" refers to a gelling agent that forms non-covalent cross-links or physical cross-links through ionic bonds. The ionic cross-linked gelling agent may include low acyl gellan gum, pectin, κ-carrageenan, ι-carrageenan, or alginate. The ionic cross-linked gelling agent may preferably include low acyl gellan gum.

[0113] The gelling agent may include one or more biopolymers. The biopolymers may be formed from polysaccharides.

[0114] Biopolymers include, for example, gellan gum (natural, low acyl gellan gum, high acyl gellan gum, preferably low acyl gellan gum), xanthan gum, alginate (algic acid), agar, guar gum, etc. The composition may preferably include xanthan gum. The composition may include two biopolymers. The composition may include three biopolymers. The composition may include two biopolymers in substantially equal weights. The composition may include three biopolymers in substantially equal weights.

[0115] The gel composition may further include a thickening agent. The thickening agent combined with the hydrogen bond cross-linked gelling agent and the ionic cross-linked gelling agent surprisingly seems to support the solid medium and maintain the gel composition, even when the gel composition includes a high level of glycerol.

[0116] The term "thickening agent" refers to a compound that increases the viscosity without causing gel formation and the mixture remains or retains fluid when homogeneously added in an amount of 0.3 wt% to a mixture of 25 °C, 50 wt% water / 50 wt% glycerol.

[0117] The gel composition preferably includes a thickening agent in the range of about 0.2 wt% to about 5 wt%, or about 0.5 wt% to about 3 wt%, or about 0.5 wt% to about 2 wt%, or about 1 wt% to about 2 wt%.

[0118] The thickening agent may include one or more of xanthan gum, carboxymethyl cellulose, microcrystalline cellulose, methyl cellulose, gum arabic, guar gum, λ-carrageenan, or starch. The thickening agent may preferably include xanthan gum.

[0119] The gel composition may further include a divalent cation. Preferably, the divalent cation includes calcium ions, such as calcium lactate in solution. For example, divalent cations (such as calcium ions) may help form the gel of a composition including a gelling agent such as an ionic cross-linked gelling agent. The ionic effect may help gel formation. The divalent cation may be present in the gel composition in the range of about 0.1 wt% to about 1 wt% or about 0.5 wt%.

[0120] The gel composition may further comprise an acid. The acid may comprise a carboxylic acid, such as levulinic acid or lactic acid.

[0121] The gel composition preferably comprises some water. When the gel composition comprises some water, the gel composition is more stable. Preferably, the water comprised in the gel composition is from about 8 wt% to about 32 wt%, or from about 15 wt% to about 25 wt%, or from about 18 wt% to about 22 wt%, or about 20 wt%.

[0122] Preferably, when the gel composition is used, the aerosol - generating substrate comprises a porous medium carrying the gel composition. The term "porous" as used herein refers to a material providing a plurality of pores or openings that allow air to pass through the material.

[0123] In certain embodiments of the present invention, the aerosol - generating article further comprises one or more elongate susceptor elements within the strip of the aerosol - generating substrate. For example, the one or more elongate susceptor elements may be disposed substantially longitudinally within the strip of the aerosol - generating substrate and be in thermal contact with the aerosol - generating substrate.

[0124] As used herein with reference to the present invention, the term "susceptor element" refers to a material capable of converting electromagnetic energy into heat. When located within a fluctuating electromagnetic field, eddy currents induced in the susceptor element cause heating of the susceptor element. Since the susceptor element is positioned in thermal contact with the aerosol - generating substrate, the aerosol - generating substrate is heated by the susceptor element.

[0125] When used to describe a susceptor element, the term "elongate" means that the length dimension of the susceptor element is greater than its width dimension or its thickness dimension, e.g., greater than twice its width dimension or its thickness dimension.

[0126] The susceptor element is disposed substantially longitudinally within the strip of the aerosol - generating substrate. This means that the length dimension of the elongate susceptor element is arranged to be generally parallel to the longitudinal direction of the strip, e.g., within plus or minus 10 degrees of the longitudinal direction of the strip. In a preferred embodiment, the elongate susceptor element may be located at a radially central position within the strip or segment and extend along the longitudinal axis of the strip or segment.

[0127] The susceptor element preferably takes the form of a pin, bar, strip or blade.

[0128] The susceptor element preferably has a width of from 1 mm to 5 mm.

[0129] The thickness of the susceptor element may generally be from 0.01 mm to 2 mm, such as from 0.5 mm to 2 mm. In some embodiments, the susceptor element preferably has a thickness of from 10 microns to 500 microns, more preferably from 10 microns to 100 microns.

[0130] Preferably, the length of the elongate susceptor element is equal to or shorter than the length of the aerosol-generating segment in which the elongate susceptor element is included. Preferably, the elongate susceptor element has the same length as the aerosol-generating segment in which the elongate susceptor element is included.

[0131] The susceptor element can be formed from any material capable of being inductively heated to a temperature sufficient to generate an aerosol from the aerosol-generating substrate. Preferably, the susceptor element comprises metal or carbon.

[0132] Preferred susceptor elements can comprise or consist of a ferromagnetic material such as a ferromagnetic alloy, ferritic iron, or ferromagnetic steel or stainless steel. Suitable susceptor elements can be aluminium or comprise aluminium.

[0133] Preferably, the strip of aerosol-generating substrate is delimited by a wrapper. The wrapper can be a paper wrapper or a non-paper wrapper.

[0134] Suitable paper wrappers for specific embodiments of the present invention are known in the art and include but are not limited to: cigarette paper; and filter tip segment wrappers. Suitable non-paper wrappers for specific embodiments of the present invention are known in the art and include but are not limited to sheets of homogenised tobacco material.

[0135] The aerosol-generating article according to the present disclosure may also include an upstream section located upstream of the strip of aerosol-generating substrate. The upstream section is preferably located immediately upstream of the strip of aerosol-generating substrate. The upstream section preferably extends between the upstream end of the aerosol-generating article and the strip of aerosol-generating substrate. The upstream section may include one or more upstream elements located upstream of the strip of aerosol-generating substrate.

[0136] The upstream element advantageously prevents direct physical contact with the upstream end of the strip of aerosol-generating substrate. In addition, the presence of the upstream element helps to prevent any loss of the substrate, which may be advantageous if the substrate contains particulate plant material, for example.

[0137] In the case where the strip of aerosol-generating substrate comprises shredded tobacco (such as tobacco cut filler), the upstream section or its elements may additionally help to prevent loss of loose tobacco particles from the upstream end of the article. This may be particularly important when the shredded tobacco has a relatively low density, for example.

[0138] The upstream element can be a porous rod element. Preferably, the upstream element has a porosity of at least 50% in the longitudinal direction of the aerosol-generating article. More preferably, the upstream element has a porosity between 50% and 90% in the longitudinal direction. The porosity of the upstream element in the longitudinal direction is defined by the ratio of the cross-sectional area of the material forming the upstream element to the internal cross-sectional area of the aerosol-generating article at the location of the upstream element.

[0139] The upstream element can be made of a porous material or can include a plurality of openings. For example, this can be achieved by laser perforation. Preferably, the plurality of openings are evenly distributed over the cross-section of the upstream element.

[0140] The porosity or permeability of the upstream element can be advantageously designed to provide a specific overall draw resistance (RTD) to the aerosol-generating article with substantially no impact on the filtration provided by other parts of the article.

[0141] The upstream element can be formed of a material impermeable to air. In such embodiments, the aerosol-generating article can be configured such that air flows into the strip of the aerosol-generating substrate through a suitable ventilation device provided in the wrapper.

[0142] The upstream element can have a density of less than 200 g / cm³, or less than 175 g / cm³, or less than 150 g / cm³. Preferably, the upstream element has a density of less than 140 g / cm³. Preferably, the density of the upstream element is less than 138 g / cm³, more preferably less than 136 g / cm³, more preferably less than 134 g / cm³, more preferably less than 132 g / cm³, more preferably less than 130 g / cm³.

[0143] The upstream element preferably has a density of at least 85 mg / cm³, more preferably at least 90 mg / cm³, more preferably at least 95 mg / cm³, more preferably at least 100 mg / cm³, more preferably at least 105 mg / cm³, more preferably at least 110 mg / cm³, more preferably at least 120 mg / cm³.

[0144] For example, the upstream element can have a density between 85 mg / cm³ and 140 g / cm³, or between 90 mg / cm³ and 138 g / cm³, or between 95 mg / cm³ and 136 g / cm³, or between 100 mg / cm³ and 134 g / cm³, or between 105 mg / cm³ and 132 g / cm³, or between 110 mg / cm³ and 130 g / cm³, or between 120 mg / cm³ and 130 mg / cm³.

[0145] A decrease in the density of the upstream element compared to the typical density of such elements increases the compressibility of the upstream element.

[0146] The upstream element is adapted to be compressible to a final density when the upstream element and a strip of the aerosol - generating substrate are inserted into the heating chamber of the aerosol - generating device. The upstream element is preferably adapted to be compressible to a final density that is at least 1.1 times the initial density, more preferably at least 1.25 times the initial density, more preferably at least 1.5 times the initial density, more preferably at least 1.75 times the initial density, more preferably twice the initial density. The upstream element can be compressed to a final density up to 4 times the initial density.

[0147] For example, the upstream element can be adapted to be compressible to a final density between 1.1 times and 4 times the initial density, or between 1.25 times and 4 times the initial density, or between 1.5 times and 4 times the initial density, or between 1.75 times and 4 times the initial density, or between 2 times and 4 times the initial density, or between 1.1 times and 3 times the initial density, or between 1.25 times and 3 times the initial density, or between 1.5 times and 3 times the initial density, or between 1.75 times and 3 times the initial density, or between 2 times and 3 times the initial density.

[0148] Preferably, the upstream element is adapted to be compressible to a final density of at least 100 mg / cubic centimeter, more preferably at least 110 mg / cubic centimeter, more preferably at least 120 mg / cubic centimeter, more preferably at least 125 mg / cubic centimeter, more preferably at least 130 mg / cubic centimeter, more preferably at least 135 mg / cubic centimeter, more preferably at least 140 mg / cubic centimeter.

[0149] Preferably, the upstream element is adapted to be compressible to a final density less than 350 mg / cubic centimeter, more preferably less than 300 mg / cubic centimeter, more preferably less than 275 mg / cubic centimeter, more preferably less than 250 mg / cubic centimeter, more preferably less than 225 mg / cubic centimeter, more preferably less than 200 mg / cubic centimeter, more preferably less than 175 mg / cubic centimeter.

[0150] For example, the upstream element is adapted to be compressible to a final density between 100 mg / cubic centimeter and 350 mg / cubic centimeter, or between 110 mg / cubic centimeter and 300 mg / cubic centimeter, or between 120 mg / cubic centimeter and 275 mg / cubic centimeter, or between 125 mg / cubic centimeter and 250 mg / cubic centimeter, or between 130 mg / cubic centimeter and 225 mg / cubic centimeter, or between 135 mg / cubic centimeter and 200 mg / cubic centimeter, or between 140 mg / cubic centimeter and 175 mg / cubic centimeter.

[0151] The upstream element can be made of any material suitable for use in an aerosol - generating article and providing a desired degree of compressibility. Suitable materials for forming the upstream element include filter materials, ceramics, polymeric materials, cellulose acetate, cardboard, zeolites, or an aerosol - generating substrate.

[0152] In a preferred embodiment, the upstream element is formed from a fibrous filter material. Particularly preferably, the upstream element is formed from a segment of a cellulose acetate tow.

[0153] Preferably, the upstream element is formed from a fibrous filter material having a denier per filament (dpf) of less than 12, or less than 8, or less than 4. More preferably, the denier per filament (dpf) is less than 3. The denier per filament (dpf) of the fibrous filter material is preferably less than 2.9, more preferably less than 2.8, more preferably less than 2.7, more preferably less than 2.6.

[0154] Preferably, the denier per filament (dpf) of the fibrous filter material is at least 2, more preferably at least 2.1, more preferably at least 2.2, more preferably at least 2.3, more preferably at least 2.4.

[0155] For example, the denier per filament (dpf) can be between 2 and 12, or between 2 and 8, or between 2 and 4, or between 2 and 3, or between 2.1 and 2.9, or between 2.2 and 2.8, or between 2.3 and 2.7, or between 2.4 and 2.6. The denier per filament can be about 2.5.

[0156] The denier per filament corresponds to the average denier of the individual fibers within the upstream element and is the weight (in grams) of a single fiber or filament that is 9000 meters in length. Thus, in the present invention, the value of dpf indicates the thickness of each fiber among the individual fibers within the upstream element. The denier per filament is expressed in denier, where 1 denier corresponds to 1 gram / 9000 meters. The dpf of a filter or filter segment can be readily determined based on measurements of the weight and length of a representative fiber sample from that filter or filter segment.

[0157] Thus, the fibrous filter material forming the upstream element has a relatively low denier per filament, which further improves the compressibility of the upstream element.

[0158] Preferably, the upstream element is formed from a fibrous filter material having a total denier of less than 30,000, more preferably less than 25,000. The total denier can be about 20,000.

[0159] The "total denier" of a filter material defines the total weight in grams of the combined fibers forming the filter material. The total denier of a filter segment thus corresponds to the denier per filament multiplied by the total number of fibers in the filter segment.

[0160] In the case where the upstream element is formed from a fibrous filter material, the fibrous filter material preferably includes a filter plasticizer. Preferably, the amount of filter plasticizer in the upstream element is less than 4% by weight based on the total weight of the upstream element (excluding the wrapper), more preferably less than 3.9% by weight based on the total weight of the upstream element, more preferably less than 3.8% by weight, more preferably less than 3.7% by weight, more preferably less than 3.6% by weight. Preferably, the amount of filter plasticizer in the upstream element is at least 3% by weight based on the total weight of the upstream element, more preferably at least 3.1% by weight, more preferably at least 3.2% by weight, more preferably at least 3.3% by weight, more preferably at least 3.4% by weight.

[0161] For example, the upstream element may have a filter plasticizer content between 3% and 4% by weight, or between 3.1% and 3.9% by weight, or between 3.2% and 3.8% by weight, or between 3.3% and 3.7% by weight, or between 3.4% and 3.6% by weight based on the total weight of the upstream element. The upstream element may have a filter plasticizer content of approximately 3.5% by weight based on the total weight of the upstream element.

[0162] Thus, the amount of filter plasticizer in the fibrous filter material is relatively low, which further improves the compressibility of the upstream element. The relatively low level of filter plasticizer can also ensure that the compression of the upstream element does not result in an unacceptable increase in the draw resistance (RTD) of the upstream element. Generally, maintaining a relatively low level of filter plasticizer will advantageously allow for better control of RTD when compressing the upstream element. Providing a higher level of filter plasticizer can make the upstream element more difficult to compress and may create unwanted channels on the outside of the upstream element during compression, which will result in an unacceptable decrease in the overall RTD.

[0163] Suitable filter plasticizers for the upstream element in the aerosol-generating article of the present invention will be known to the person skilled in the art. Preferably, the filter plasticizer is triacetin. Preferably, the upstream element comprises a cellulose acetate tow with triacetin as the filter plasticizer.

[0164] The upstream element may alternatively be formed from cardboard or paper material.

[0165] In certain preferred embodiments, the upstream element is formed from a solid cylindrical rod element having a filled cross-section. Such rod elements may be referred to as "ordinary" elements. The solid rod element may be porous but does not have a tubular form and thus does not provide any longitudinal flow channels. The solid rod element preferably has a substantially uniform cross-section.

[0166] In such embodiments, the upstream element preferably has a draw resistance (RTD) of less than 25 mm H2O, or less than 22 mm H2O, or less than 20 mm H2O. Preferably, in such embodiments, the upstream element has an RTD of at least 10 mm H2O, or at least 12 mm H2O, or at least 14 mm H2O, or at least 16 mm H2O. For example, the upstream element may have an RTD between 10 mm H2O and 25 mm H2O, or between 12 mm H2O and 22 mm H2O, or between 14 mm H2O and 20 mm H2O, or between 16 mm H2O and 20 mm H2O.

[0167] In other embodiments, the upstream element is formed from a hollow tubular segment that defines a longitudinal cavity providing an unrestricted flow path. In such embodiments, as described above, the upstream element can provide protection for the aerosol-forming substrate while having a minimal impact on the overall draw resistance (RTD) and filtration characteristics of the article.

[0168] Preferably, the diameter of the longitudinal cavity of the hollow tubular segment forming the upstream element is at least about 4 mm, more preferably at least about 4.5 mm, more preferably at least about 5 mm, and more preferably at least about 5.5 mm. Preferably, the diameter of the longitudinal cavity is maximized in order to minimize the RTD of the upstream section or its upstream element. The inner diameter of the upstream element can be about 5.1 mm.

[0169] Preferably, the wall thickness of the hollow tubular segment is less than about 2 mm, more preferably less than about 1.5 mm, and more preferably less than about 1.25 mm. The wall thickness of the hollow tubular segment defining the upstream element can be about 1 mm.

[0170] In such embodiments, the upstream element preferably has an RTD of less than 10 mm H2O, more preferably less than 5 mm H2O, more preferably less than 2.5 mm H2O. Preferably, in such embodiments, the upstream element has an RTD of at least 0.1 mm H2O, or at least about 0.25 mm H2O, or at least about 0.5 mm H2O. For example, the upstream element may have an RTD between 0.1 mm H2O and 10 mm H2O, or between 0.25 mm H2O and 5 mm H2O, or between 0.5 mm H2O and 2.5 mm H2O.

[0171] Preferably, prior to insertion of the aerosol-generating article into the aerosol-generating device, the upstream element has an outer diameter that is substantially equal to the outer diameter of the aerosol-generating article. Preferably, the outer diameter of the upstream element is between 6 mm and 8 mm before any compression, more preferably between 7 mm and 7.5 mm. Preferably, the upstream element has an outer diameter of about 7.1 mm.

[0172] Preferably, the upstream element has a length between 2 millimeters and 8 millimeters, more preferably between 3 millimeters and 7 millimeters, and even more preferably between 4 millimeters and 6 millimeters. In a particularly preferred embodiment, the upstream element has a length of approximately 5 millimeters. The length of the upstream section or the upstream element can advantageously vary in order to provide the desired overall length of the aerosol-generating article. For example, in the case where it is desired to reduce the length of one of the other components of the aerosol-generating article, the length of the upstream section or the upstream element can be increased in order to maintain the same overall length of the article.

[0173] Furthermore, for articles intended to be externally heated, the length of the upstream element can be used to control the position of the aerosol-generating article within the heating chamber of the aerosol-generating device. This can advantageously ensure that the position of the aerosol-generating substrate within the heating chamber can be optimized for heating, and also the position of any ventilation can be optimized.

[0174] The upstream element is preferably defined by a wrapper such as a rod wrapper. The wrapper defining the upstream element is preferably adapted such that when the aerosol-generating article is inserted into the aerosol-generating device, it allows the necessary compression of the upstream element.

[0175] Preferably, the upstream element is defined by a wrapper having a thickness of less than 50 micrometers, more preferably less than 45 micrometers, more preferably less than 40 micrometers, more preferably less than 35 micrometers, and even more preferably less than 30 micrometers.

[0176] Preferably, the upstream element is defined by a wrapper having a basis weight of less than 35 grams per square meter, more preferably less than 30 grams per square meter, more preferably less than 25 grams per square meter, and even more preferably less than 20 grams per square meter.

[0177] Thus, the wrapper defining the upstream element preferably has a relatively low thickness and basis weight such that the wrapper can achieve the required compression level of the upstream element.

[0178] The upstream element is preferably connected to the strip of the aerosol-generating substrate and at least a portion of the optional downstream section by means of an outer wrapper as described herein. Preferably, the outer wrapper also has a relatively low thickness and basis weight in order to achieve the required compression level of the upstream element and the aerosol-generating substrate.

[0179] Preferably, the outer wrapper has a thickness of less than 75 micrometers, more preferably less than 70 micrometers, more preferably less than 65 micrometers, more preferably less than 60 micrometers, and even more preferably less than 55 micrometers.

[0180] Preferably, the upstream element is defined by a wrapper having a basis weight of less than 50 grams per square meter, more preferably less than 45 grams per square meter, more preferably less than 40 grams per square meter, and even more preferably less than 35 grams per square meter.

[0181] The aerosol-generating article of the aerosol-generating system according to the present invention preferably further comprises a downstream section located downstream of the strip of aerosol-generating substrate. The downstream section is preferably located immediately downstream of the strip of aerosol-generating substrate. The downstream section of the aerosol-generating article preferably extends between the strip of aerosol-generating substrate and the downstream end of the aerosol-generating article. The downstream section may include one or more elements, each of which will be described in more detail within the present disclosure.

[0182] The length of the downstream section may be between 20 millimeters and 70 millimeters, or between 25 millimeters and 60 millimeters, or between 30 millimeters and 50 millimeters.

[0183] The downstream section preferably includes a hollow tubular cooling element disposed downstream of the strip of aerosol-generating substrate. The hollow tubular cooling element may advantageously provide an aerosol cooling element for the aerosol-generating article.

[0184] The hollow tubular cooling element may be arranged immediately downstream of the strip of aerosol-generating substrate. In other words, the hollow tubular cooling element may abut the downstream end of the strip of aerosol-generating substrate. The hollow tubular cooling element may define the upstream end of the downstream section of the aerosol-generating article. The downstream end of the aerosol-generating article may coincide with the downstream end of the downstream section. In some embodiments, the downstream section of the aerosol-generating article includes a single hollow tubular element. In other words, the downstream section of the aerosol-generating article may include only one hollow tubular element. In other embodiments, as described below, the downstream section includes two or more hollow tubular elements.

[0185] As used throughout the present disclosure, the term "hollow tubular element" refers to a generally elongated element that defines a lumen or air flow passage along its longitudinal axis.

[0186] In the context of the present invention, the hollow tubular cooling element provides an unconstrained flow channel. This means that the hollow tubular cooling element provides a negligible suction resistance (RTD) level. The term "negligible RTD level" is used to describe an RTD of less than 1 millimeter H2O / 10 millimeter length of the hollow tubular cooling element, preferably less than 0.4 millimeter H2O / 10 millimeter length of the hollow tubular cooling element, more preferably less than 0.1 millimeter H2O / 10 millimeter length of the hollow tubular cooling element.

[0187] The RTD of the hollow tubular cooling element is preferably less than or equal to 10 millimeters H2O, or less than or equal to 5 millimeters H2O, or less than or equal to 2.5 millimeters H2O, or less than or equal to 2 millimeters H2O, or less than or equal to 1 millimeter H2O.

[0188] The RTD of the hollow tubular cooling element can be at least 0 mm H2O, or at least 0.25 mm H2O, or at least 0.5 mm H2O, or at least 1 mm H2O.

[0189] Therefore, the flow channel should be free of any components that would impede the flow of air in the longitudinal direction. Preferably, the flow channel is substantially empty, and particularly preferably the flow channel is empty.

[0190] The aerosol-generating article may include a ventilation zone at a position along the downstream section. In some embodiments, the aerosol-generating article may include a ventilation zone at a position along the hollow tubular cooling element. This ventilation zone or any ventilation zone may extend through the outer peripheral wall of the hollow tubular cooling element. Thus, a fluid communication is established between the flow channel defined inside the hollow tubular cooling element and the external environment. The ventilation zone is further described within the present disclosure.

[0191] The length of the hollow tubular cooling element can be between 15 mm and 50 mm, or between 20 mm and 45 mm, or between 20 mm and 40 mm, or between 20 mm and 30 mm, or between 25 mm and 40 mm, or between 30 mm and 40 mm.

[0192] The wall thickness of the hollow tubular cooling element can be between 100 μm and 2 mm, or between 150 μm and 1.5 mm, or between 200 μm and 1.25 mm.

[0193] The hollow tubular cooling element preferably has an outer diameter that is substantially equal to the outer diameter of the strip of the aerosol-generating substrate and the outer diameter of the aerosol-generating article.

[0194] Preferably, the outer diameter of the hollow tubular cooling element is between 5 mm and 12 mm, more preferably between 6 mm and 10 mm, and even more preferably between 7 mm and 8 mm. In some embodiments, the outer diameter of the hollow tubular cooling element can be less than 7 mm, for example, between 5 mm and 7 mm, or between 6 mm and 7 mm.

[0195] Preferably, the hollow tubular cooling element can have a constant inner diameter along the length of the hollow tubular cooling element. However, the inner diameter of the hollow tubular cooling element can vary along the length of the hollow tubular cooling element.

[0196] The hollow tubular cooling element can have an inner diameter of at least 2 mm. For example, the hollow tubular cooling element can have an inner diameter of at least 3 mm, at least 4 mm, or at least 5 mm.

[0197] The hollow tubular cooling element can have an inner diameter of no more than 10 mm. For example, the hollow tubular cooling element can have an inner diameter of no more than 9 mm, no more than 8 mm, or no more than 7 mm.

[0198] The hollow tubular cooling element may have an inner diameter between 2 millimeters and 10 millimeters, between 3 millimeters and 9 millimeters, between 4 millimeters and 8 millimeters, or between 5 millimeters and 7 millimeters.

[0199] The lumen or cavity of the hollow tubular cooling element may have any cross-sectional shape. The lumen of the hollow tubular cooling element may have a circular cross-sectional shape.

[0200] The hollow tubular cooling element may comprise a paper-based material. The hollow tubular cooling element may comprise at least one paper layer. The paper may be very hard paper. The paper may be curled paper, such as curled heat-resistant paper or curled parchment paper.

[0201] Preferably, the hollow tubular cooling element may comprise cardboard. The hollow tubular cooling element may be a cardboard tube. The hollow tubular cooling element may be formed of cardboard.

[0202] The hollow tubular cooling element may be a paper tube. The hollow tubular cooling element may be a tube formed by helically winding paper. The hollow tubular cooling element may be formed of multiple paper layers. The paper may have a basis weight of at least 50 grams per square meter, at least 60 grams per square meter, at least 70 grams per square meter, or at least 90 grams per square meter.

[0203] The hollow tubular cooling element may comprise a polymeric material. For example, the hollow tubular cooling element may comprise a polymeric film. The polymeric film may comprise a cellulose film. The hollow tubular cooling element may comprise high-density polyethylene (HDPE) or polyhydroxyalkanoate (PHA) fibers. The hollow tube may comprise a cellulose acetate tow.

[0204] In cases where the hollow tubular cooling element comprises a cellulose acetate tow, the cellulose acetate tow may have a denier per filament between 2 and 4 and a total denier between 25,000 and 40,000.

[0205] In some embodiments, the aerosol-generating article of the aerosol-generating system according to the present invention may comprise a ventilation zone at a position along the downstream section. More specifically, in those embodiments where the downstream section comprises a hollow tubular cooling element, the ventilation zone may be provided at a position along the hollow tubular cooling element.

[0206] The ventilation zone generally may comprise a plurality of perforations through the outer peripheral wall of the hollow tubular cooling element. Preferably, the ventilation zone comprises at least one row of circumferential perforations. In some embodiments, the ventilation zone may comprise two rows of circumferential perforations. For example, the perforations may be formed on a production line during the manufacture of the aerosol-generating article. Preferably, each row of circumferential perforations comprises 8 to 30 perforations.

[0207] The aerosol-generating article of the aerosol-generating system of the present invention may have a ventilation level of at least 25%.

[0208] Throughout this specification, the term "ventilation level" is used to denote the volume ratio of the airflow entering the aerosol-generating article via the ventilation zone (ventilation airflow) to the sum of the aerosol airflow and the ventilation airflow. The greater the ventilation level, the higher the dilution of the aerosol stream delivered to the consumer. The aerosol-generating article preferably has a ventilation level of at least 25%, more preferably at least 30%, even more preferably at least 40%, and even more preferably at least 50%.

[0209] The aerosol-generating article of the aerosol-generating system of the present invention can have a ventilation level of up to 90%. Preferably, the ventilation level of the aerosol-generating article according to the present invention is less than or equal to 80%, more preferably less than or equal to 70%, and even more preferably less than or equal to 60%.

[0210] For example, the aerosol-generating article of the aerosol-generating system of the present invention can have a ventilation level of 25% to 90%, preferably 30% to 80%, more preferably 40% to 70%, and even more preferably 50% to 60%.

[0211] The downstream section may also include a downstream filter segment. The downstream filter segment may extend to the downstream end of the downstream section. The downstream filter segment may be located at the downstream end of the aerosol-generating article. The downstream end of the downstream filter segment may define the downstream end of the aerosol-generating article.

[0212] The downstream filter segment may be located downstream of the hollow tubular cooling element as described above. The downstream filter segment may extend between the hollow tubular cooling element and the downstream end of the aerosol-generating article.

[0213] The downstream filter segment is preferably a solid rod, which may also be described as a "plain" rod and is non-tubular. Thus, the filter segment preferably has a substantially uniform cross-section.

[0214] The downstream filter segment is preferably formed of a fibrous filter material. The fibrous filter material can be used to filter the aerosol generated by the aerosol-generating matrix. Suitable fibrous filter materials will be known to those skilled in the art. Particularly preferably, at least one downstream filter segment includes a cellulose acetate filter segment formed of a cellulose acetate tow.

[0215] In certain preferred embodiments, the downstream section includes a single downstream filter segment. In alternative embodiments, the downstream section includes two or more downstream filter segments axially aligned in an end-to-end adjacent relationship with each other.

[0216] Preferably, the downstream filter segment has a low particle filtration efficiency.

[0217] Preferably, the downstream filter segment is defined by a rod wrapper. Preferably, the downstream filter segment is non-ventilated such that air does not enter the aerosol-generating article along the downstream filter segment.

[0218] The downstream filter segment is preferably connected to one or more of the adjacent upstream components of the aerosol-generating article by means of a tipping wrapper.

[0219] The downstream filter segment preferably has an outer diameter that is substantially equal to the outer diameter of the aerosol-generating article. The outer diameter of the downstream filter segment may be substantially the same as the outer diameter of the hollow tubular cooling element.

[0220] Preferably, the outer diameter of the downstream filter segment is between 5 mm and 12 mm, more preferably between 6 mm and 10 mm, and even more preferably between 7 mm and 8 mm. In some embodiments, the outer diameter of the downstream filter segment may be less than 7 mm, such as between 5 mm and 7 mm, or between 6 mm and 7 mm.

[0221] As described above, the downstream filter segment may be formed from a fibrous filter material. The downstream filter segment may be formed from a porous material. The downstream filter segment may be formed from a biodegradable material. The downstream filter segment may be formed from a cellulose material such as cellulose acetate.

[0222] The downstream filter segment may be formed from a polylactic acid-based material. The downstream filter segment may be formed from a bioplastic material (preferably a starch-based bioplastic material). The downstream filter segment may be made by injection molding or by extrusion.

[0223] The length of the downstream filter segment may be between 5 mm and 25 mm, or between 10 mm and 25 mm, or between 5 mm and 20 mm, or between 10 mm and 20 mm.

[0224] The downstream section may also include one or more additional hollow tubular elements.

[0225] In certain embodiments, the downstream section may include a hollow tubular support element upstream of the hollow tubular cooling element described above. Preferably, the hollow tubular support element abuts the downstream end of the strip of aerosol-generating substrate. Preferably, the hollow tubular support element abuts the upstream end of the hollow tubular cooling element. Preferably, the hollow tubular support element and the hollow tubular cooling element are adjacent to each other and together provide a hollow tubular section within the downstream section.

[0226] Preferably, the hollow tubular support element is compressible.

[0227] The hollow tubular support element can be formed from any suitable material or combination of materials. For example, the support element can be formed from one or more materials selected from the following: cellulose acetate; cardboard; curled paper, such as curled heat-resistant paper or curled parchment; and polymeric materials, such as low density polyethylene (LDPE). In a preferred embodiment, the support element is formed from cellulose acetate. Other suitable materials include polyhydroxyalkanoate (PHA) fibers. In a preferred embodiment, the hollow tubular support element comprises a hollow acetate tube.

[0228] The hollow tubular support element preferably has an outer diameter that is substantially equal to the outer diameter of the strip of the aerosol-forming substrate and the outer diameter of the aerosol-generating article.

[0229] Preferably, the outer diameter of the hollow tubular support element is between 5 mm and 12 mm, more preferably between 6 mm and 10 mm, and even more preferably between 7 mm and 8 mm. In some embodiments, the outer diameter of the hollow tubular support element can be less than 7 mm, for example, between 5 mm and 7 mm, or between 6 mm and 7 mm.

[0230] The hollow tubular support element can have a wall thickness of at least 1 mm, preferably at least 1.5 mm, and more preferably at least 2 mm.

[0231] The hollow tubular support element can have a length of between 5 mm and 15 mm, preferably between 6 mm and 15 mm, and more preferably between 7 mm and 15 mm. In other embodiments, the support element has a length of between 5 mm and 12 mm, preferably between 6 mm and 12 mm, and more preferably between 7 mm and 12 mm. In further embodiments, the support element has a length of between 5 mm and 10 mm, preferably between 6 mm and 10 mm, and more preferably between 7 mm and 10 mm.

[0232] Preferably, the hollow tubular support element is adapted such that it can be compressed to a similar extent as the strip of the aerosol-forming substrate. This enables at least an upstream portion of the hollow tubular support element to be compressed in order to insert the aerosol-generating article into a heating device. Partial compression of the hollow tubular support element may be required in an aerosol-generating system in which the strip of the aerosol-forming substrate is fully received in a heating chamber and the upstream end of the hollow tubular segment can also be received in the heating chamber.

[0233] Preferably, the hollow tubular support element comprises an outer peripheral wall having a density of less than 200 mg / cubic centimeter, more preferably less than 175 mg / cubic centimeter, more preferably less than 150 mg / cubic centimeter, more preferably less than 140 mg / cubic centimeter, and even more preferably less than 130 mg / cubic centimeter.

[0234] Alternatively or in addition to the hollow tubular support element, the downstream section may also include a downstream hollow tubular element downstream of the hollow tubular cooling element.

[0235] After the aerosol-generating article is inserted into the aerosol-generating device, the overall RTD of the aerosol-generating article is preferably at least 10 mm H2O, more preferably at least 15 mm H2O, more preferably at least 20 mm H2O, more preferably at least 25 mm H2O, more preferably at least 30 mm H2O.

[0236] After the aerosol-generating article is inserted into the aerosol-generating device, the overall RTD of the aerosol-generating article is preferably not more than 70 mm H2O, more preferably not more than 60 mm H2O, more preferably not more than 55 mm H2O, more preferably not more than 50 mm H2O, more preferably not more than 45 mm H2O.

[0237] For example, after the aerosol-generating article is inserted into the aerosol-generating device, the overall RTD of the aerosol-generating article may be between 10 mm H2O and 70 mm H2O, or between 15 mm H2O and 60 mm H2O, or between 20 mm H2O and 55 mm H2O, or between 25 mm H2O and 45 mm H2O, or between 30 mm H2O and 45 mm H2O.

[0238] The aerosol-generating article preferably has an overall length of 40 mm to 80 mm, or 40 mm to about 70 mm, or 40 mm to about 60 mm, or 45 mm to about 80 mm, or about 45 mm to about 70 mm, or 45 mm to 60 mm, or 50 mm to 80 mm, or 50 mm to about 70 mm, or about 50 mm to about 60 mm. In an exemplary embodiment, the overall length of the aerosol-generating article is about 45 mm.

[0239] The aerosol-generating article preferably has an outer diameter of about 5 mm to about 12 mm, or about 6 mm to about 12 mm, or about 7 mm to about 12 mm, or about 5 mm to about 10 mm, or about 6 mm to about 10 mm, or about 7 mm to about 10 mm, or about 5 mm to about 8 mm, or about 6 mm to about 8 mm, or about 7 mm to about 8 mm. In other embodiments, the aerosol-generating article has an outer diameter of less than 7 mm.

[0240] Before the aerosol-generating article is inserted into the aerosol-generating device, the outer diameter of the aerosol-generating article may be substantially constant over the entire length of the article. As an alternative, different parts of the aerosol-generating article may have different outer diameters. In particular, after the aerosol-generating article is inserted into the aerosol-generating device, the strips of the aerosol-generating substrate may have different outer diameters.

[0241] In a particularly preferred embodiment, one or more of the components of the aerosol-generating article are individually delimited by their own packaging.

[0242] Preferably, at least one component of the aerosol-generating article is packaged in a hydrophobic packaging.

[0243] The term "hydrophobic" refers to a surface that exhibits water-repellent properties. A useful way to determine this is to measure the water contact angle. The "water contact angle" is the angle, measured conventionally through the liquid, when the liquid / vapor interface meets the solid surface. It quantifies the wettability of the solid surface by the liquid via Young's equation. Hydrophobicity or the water contact angle can be determined by using the TAPPI T558 test method, and the result is presented as the interfacial contact angle and reported in "degrees", and the range can be from close to zero to close to 180 degrees.

[0244] In a preferred embodiment, the hydrophobic packaging is a packaging including a paper layer having a water contact angle of about 30 degrees or greater, and preferably about 35 degrees or greater, or about 40 degrees or greater, or about 45 degrees or greater.

[0245] For example, the paper layer may contain PVOH (polyvinyl alcohol) or silicon. PVOH can be applied as a surface coating to the paper layer, or the paper layer may include a surface treatment containing PVOH or silicon.

[0246] As defined above, the aerosol-generating system according to the present invention further includes an aerosol-generating device for heating the aerosol-generating substrate of the aerosol-generating article during use. The aerosol-generating article is adapted to be inserted by a consumer into the aerosol-generating device. The aerosol-generating device includes a body defining a heating chamber for removably receiving at least a portion of a strip of the aerosol-generating substrate when the aerosol-generating article is inserted into the aerosol-generating device. The heating chamber includes a heater assembly disposed along at least a portion of the heating chamber for heating the strip of the aerosol-generating substrate.

[0247] As used herein with reference to the present invention, the term "heater assembly" refers to the component of the aerosol-generating device responsible for heating the aerosol-generating substrate of the aerosol-generating article. As will be elaborated in more detail below, the heater assembly can directly heat the aerosol-generating substrate, which may be the case where the heater assembly includes a resistive heater. The heater assembly can indirectly heat the aerosol-generating substrate, which may be the case where the heater assembly includes an induction coil.

[0248] The heating chamber of the aerosol-generating device may include an open downstream end and a closed upstream end. In use, the upstream end of the aerosol-generating device may be inserted into the open downstream end of the heating chamber. In use, the upstream end of the aerosol-generating article may abut the upstream end of the heating chamber. Alternatively, the upstream end of the aerosol-generating article may abut another component within the heating chamber to prevent further upstream movement of the aerosol-generating article.

[0249] As used herein with reference to the present invention, the term "fully received" refers to the position when the aerosol-generating article is inserted into the heating chamber to the greatest extent possible. This may be when the upstream end of the aerosol-generating article abuts the upstream end of the heating chamber. Alternatively, this may be when the upstream end of the aerosol-generating article abuts another component within the heating chamber to prevent further upstream movement of the aerosol-generating article. When the aerosol-generating article is "fully received" in the heating chamber, a portion of the aerosol-generating article may protrude from the open downstream end of the aerosol-generating article. For example, this may be the case when the length of the aerosol-generating article is greater than the length of the heating chamber, or when the length of the aerosol-generating article is greater than the distance between the downstream end of the heating chamber and the component (if present) within the heating chamber that prevents further upstream movement of the aerosol-generating article.

[0250] The length of the heating chamber may be between 15 millimeters and 80 millimeters. Preferably, the length of the heating chamber is between 20 millimeters and 70 millimeters. More preferably, the length of the heating chamber is between 25 millimeters and 60 millimeters. Even more preferably, the length of the heating chamber is between 25 millimeters and 50 millimeters.

[0251] The length of the heating chamber may be between 25 millimeters and 29 millimeters. Preferably, the length of the heating chamber is between 25 millimeters and 29 millimeters. More preferably, the length of the heating chamber is between 26 millimeters and 29 millimeters. Even more preferably, the length of the heating chamber is 27 millimeters or 28 millimeters.

[0252] The length of the heating chamber may be equal to or greater than the length of the strip of the aerosol-generating substrate. Preferably, the length of the heating chamber is such that when the aerosol-generating article is fully received in the heating chamber, at least 75% of the strip of the aerosol-generating substrate is inserted or received within the device heating chamber. More preferably, the length of the heating chamber is such that when the aerosol-generating article is fully received in the heating chamber, at least 80% of the strip of the aerosol-generating substrate is inserted or received within the heating chamber. Even more preferably, the length of the heating chamber is such that when the aerosol-generating article is fully received in the heating chamber, at least 90% of the strip of the aerosol-generating substrate is inserted or received within the heating chamber. This maximizes the length of the strip of the aerosol-generating substrate, which can be heated along its length during use, thereby optimizing the generation of aerosol from the aerosol-generating substrate and reducing waste.

[0253] The length of the heating chamber can be such that a downstream section or a portion thereof is configured to protrude from the heating chamber when the aerosol-generating article is fully received within the heating chamber. The length of the heating chamber can be such that a portion of the downstream section is configured to be received within the heating chamber when the aerosol-generating article is fully received within the heating chamber.

[0254] As defined above, the heating chamber is configured such that when the aerosol-generating article is inserted into the aerosol-generating device, there is a deformation or transformation of the strip of aerosol-generating substrate. Thus, the shape and dimensions of the heating chamber are configured relative to the shape and dimensions of the strip of aerosol-generating substrate so as to cause a desired deformation or transformation of the aerosol-generating substrate when the strip of aerosol-generating substrate is inserted into the heating chamber. In particular, the cross-section of the heating chamber is adapted such that inserting the strip of aerosol-generating substrate into the heating chamber causes at least one of the following: an increase in the density of the aerosol-generating substrate, a decrease in the cross-sectional area, and an increase in the maximum diameter of the strip of aerosol-generating substrate.

[0255] Preferably, the cross-sectional area of the heating chamber is smaller than the initial cross-sectional area of the strip of aerosol-generating substrate.

[0256] In a preferred embodiment of the present invention, the heating chamber includes a pair of opposing flat surfaces configured to receive therebetween the strip of aerosol-generating substrate. The resulting heating assembly is preferably flat. The aerosol-generating device can also be flat. Preferably, the opposing flat surfaces are fixed relative to each other within the heating chamber. The heater assembly preferably includes a heater element disposed on or near at least one of the opposing flat surfaces. Preferably, the heater assembly includes heater elements disposed on or near each of the opposing flat surfaces so as to heat the strip of aerosol-generating substrate from both sides. In such an arrangement, the heater assembly includes a pair of opposing heater elements that heat the strip of aerosol-generating substrate from opposite sides. The opposing heater elements are preferably also flat so as to provide a flat heating assembly.

[0257] As used herein, the term "flat" refers to a feature that extends substantially in a two-dimensional plane. Defining the surface of the heating chamber as "flat" means that the surface of the heating chamber extends substantially in a two-dimensional plane. Thus, the surface has a minimum curvature and preferably no curvature. Using a heating chamber that includes opposing flat surfaces on which heater elements are disposed increases the contact area between the heater elements and the strip of aerosol-generating substrate, such that the aerosol-generating substrate can be heated more effectively. The spacing between the opposing heater elements can also be adapted such that the distance between them is relatively small and heat can be effectively transferred through the strip of aerosol-generating substrate at all times.

[0258] In such embodiments, a pair of opposite flat surfaces of the heating chamber are preferably substantially parallel to each other such that the spacing between the opposite flat surfaces is substantially the same along the length of the heating chamber. Thus, the heating chamber preferably has a substantially rectangular cross-section.

[0259] The average spacing between a pair of opposite flat surfaces of the heating chamber is preferably less than 5 mm, more preferably less than 4.5 mm, more preferably less than 4 mm, more preferably less than 3.5 mm, more preferably less than 3 mm. The average spacing between a pair of opposite flat surfaces of the heating chamber is preferably at least 2 mm, more preferably at least 2.5 mm. Thus, the average spacing can be between 2 mm and 5 mm, or between 2 mm and 4.5 mm, or between 2 mm and 4 mm, or between 2 mm and 3.5 mm, or between 2 mm and 3 mm, or between 2.5 mm and 5 mm, or between 2.5 mm and 4.5 mm, or between 2.5 mm and 4 mm, or between 2.5 mm and 3.5 mm, or between 2.5 mm and 3 mm.

[0260] Thus, the average spacing between a pair of opposite surfaces of the heating chamber is typically significantly less than the diameter or maximum diameter of the strip of aerosol-generating substrate before it is inserted into the aerosol-generating device.

[0261] Preferably, the average spacing between a pair of opposite surfaces of the heating chamber is at least 1 mm less than the maximum diameter of the strip of aerosol-generating substrate before the aerosol-generating article is inserted into the aerosol-generating device. More preferably, the spacing between a pair of opposite surfaces of the heating chamber is at least 1.5 mm, or at least 2 mm, or at least 2.5 mm, or at least 3 mm less than the maximum diameter of the strip of aerosol-generating substrate before the aerosol-generating article is inserted into the aerosol-generating device. The spacing between a pair of opposite surfaces of the heating chamber can be up to 6 mm or up to 5 mm less than the maximum diameter of the strip of aerosol-generating substrate before the aerosol-generating article is inserted into the aerosol-generating device.

[0262] Preferably, the ratio of the initial outer diameter of the strip of aerosol-generating substrate to the spacing between a pair of opposite surfaces of the heating chamber is at least 1.5, more preferably at least 1.75, more preferably at least 2, more preferably at least 2.25. This ratio indicates the degree of compression of the strip of aerosol-generating substrate required to insert the strip of aerosol-generating substrate into the heating chamber.

[0263] Preferably, the heating chamber includes a funnel-shaped portion at the open downstream end, which has a cross-sectional area that gradually decreases from the downstream end towards the upstream end. This funnel-shaped portion can advantageously facilitate the insertion of the strip of aerosol-generating substrate into the heating chamber and, in particular, the gradual compression or flattening of the strip of aerosol-generating substrate from its initial shape to its final compressed shape.

[0264] In other preferred embodiments of the present invention, the heating chamber may include a pair of movable walls, wherein at least one of the movable walls includes a heater element on its inner surface. The movable walls are adapted such that they can move relative to each other between an open position and a closed position. In the open position, the movable walls are separated from each other such that a strip of aerosol - forming substrate can be inserted between them. The movable walls can then move towards each other to the closed position, where the walls enclose the strip of aerosol - forming substrate. Once the movable walls have been closed together to their closed position, the strip of aerosol - forming substrate is held between the walls in contact with their inner surfaces.

[0265] The movable walls are adapted such that upon closing the movable walls, a desired compression and flattening of the strip of aerosol - forming substrate occurs. In such embodiments, after the aerosol - generating article is inserted into the aerosol - generating device, the strip of aerosol - forming substrate is thus compressed in a single step. This can facilitate the insertion of the aerosol - generating article into the aerosol - generating device and the compression of the strip of aerosol - forming substrate.

[0266] Preferably, in the closed position, the movable walls have an average spacing within the range described above for the embodiment where a pair of flat opposing surfaces are provided within the heating chamber. The aerosol - generating device may be provided with means for locking the movable walls in the closed position during use such that a desired level of compression can be maintained during heating.

[0267] Preferably, the movable walls are connected to each other at one end such that the movable walls form a jaw - like arrangement and can pivot relative to each other between the open position and the closed position. This optimizes the degree of opening of the movable walls relative to each other to facilitate the insertion of the aerosol - generating article into the aerosol - generating device.

[0268] The heater assembly may include a single heater element or a plurality of heater elements. Any suitable type of heater element can be used. The heater assembly may include at least one of a resistive heating element and an inductive heating assembly. The heater assembly may include an external heater or an external heating element.

[0269] When the aerosol - generating article is received within the aerosol - generating device, the heater assembly can externally heat the strip of aerosol - forming substrate. When the strip of aerosol - forming substrate is received within the heating chamber of the aerosol - generating device, such an external heater assembly can be provided on at least one side of the strip of aerosol - forming substrate. Preferably, as described above, an external heater assembly is provided that heats the strip of aerosol - forming substrate on opposite sides.

[0270] The heater assembly may include at least one resistive heating element. The at least one resistive heating element can be any suitable type of resistive heating element. In some embodiments, the heater assembly includes only one resistive heating element. In some embodiments, the heater assembly includes a plurality of resistive heating elements. The heater may include at least one resistive heating element. Preferably, the heater assembly includes a plurality of resistive heating elements. Preferably, the resistive heating elements are electrically connected in a parallel arrangement. Advantageously, providing a plurality of resistive heating elements electrically connected in a parallel arrangement can facilitate delivering a desired amount of power to the heater while reducing or minimizing the voltage required to provide the desired amount of power. Advantageously, reducing or minimizing the voltage required to operate the heater can facilitate reducing or minimizing the physical size of the power source.

[0271] In some embodiments, the at least one heating element includes an electrically insulating substrate on which the at least one resistive heating element is disposed.

[0272] In some embodiments, the heater assembly includes an induction heating assembly. The induction heating assembly may include an inductor coil. The aerosol generating device may include a power source configured to supply a high-frequency oscillating current to the inductor coil.

[0273] The heater assembly may include an inductive heating element. The inductive heating element can be a susceptor element. In these embodiments, the susceptor element is preferably positioned in contact with the aerosol-forming substrate. In some embodiments, the susceptor element is located within the aerosol generating device. In these embodiments, the susceptor element may be located within the heating chamber. The aerosol generating device may include only one susceptor element. The aerosol generating device may include a plurality of susceptor elements. In some embodiments, the susceptor elements are preferably arranged to heat the outer surface of the aerosol-forming substrate.

[0274] In the case where the heater assembly includes both an inductor coil and an inductive heating element, the heating zone is defined as the longitudinal space between the most upstream portion of the inductor coil and the inductive heating element, and the longitudinal space between the most downstream portion of the inductor coil and the inductive heating element.

[0275] The susceptor element can include any suitable material. Suitable materials for an elongate susceptor element include graphite, molybdenum, silicon carbide, stainless steel, niobium, aluminum, nickel, nickel-containing compounds, titanium, and metal material composites. Some susceptor elements include metal or carbon. Advantageously, the susceptor element can include or be composed of a ferromagnetic material, such as ferritic iron, ferromagnetic alloys (such as ferromagnetic steel or stainless steel), ferromagnetic particles, and ferrites. A suitable susceptor element can be aluminum or include aluminum.

[0276] As described in more detail above, in some embodiments in which the aerosol-generating device includes an induction coil, the aerosol-generating article may include at least one susceptor element.

[0277] In some embodiments, the aerosol-generating device may include at least one resistive heating element and at least one inductive heating assembly. In some embodiments, the aerosol-generating device may include a combination of a resistive heating element and an inductive heating assembly.

[0278] The aerosol-generating device may include an airflow passage extending between an inlet and an outlet of the passage. The airflow passage may be configured to establish fluid communication between the interior of the device chamber and the exterior of the aerosol-generating device. The airflow passage of the aerosol-generating device may be defined within the body of the aerosol-generating device to effect fluid communication between the interior of the heating chamber and the exterior of the aerosol-generating device. When the aerosol-generating article is received within the heating chamber, the airflow passage may be configured to supply an airflow to the article in order to deliver the generated aerosol to a user who draws through the mouth end of the article.

[0279] The aerosol-generating device may include a power source. The power source may be a DC power source. In some embodiments, the power source is a battery.

[0280] The following provides a non-exhaustive list of non-limiting examples. Any one or more features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0281] EX1. An aerosol-generating system, the aerosol-generating system comprising:

[0282] An aerosol-generating article, the aerosol-generating article comprising a strip of aerosol-generating substrate and a downstream section extending from a downstream end of the strip of aerosol-generating substrate to a mouth end of the aerosol-generating article; and

[0283] An aerosol-generating device, the aerosol-generating device comprising a body defining a heating chamber for removably receiving at least a portion of the strip of aerosol-generating substrate of the aerosol-generating article when the aerosol-generating article is inserted into the aerosol-generating device; and a heater assembly disposed along at least a portion of the heating chamber for heating the strip of aerosol-generating substrate when the aerosol-generating article is received within the aerosol-generating device.

[0284] EX2. The aerosol - generating system according to Example EX1, wherein the strip of the aerosol - generating substrate has an initial density before the aerosol - generating article is inserted into the aerosol - generating device, and the cross - section of the heating chamber of the aerosol - generating device is configured such that when the strip of the aerosol - generating substrate is inserted into the heating chamber, the strip of the aerosol - generating substrate is compressed to a final density, and the final density is at least 1.1 times the initial density.

[0285] EX3. The aerosol - generating system according to Example EX1 or EX2, wherein the initial density of the strip of the aerosol - generating substrate is less than 300 mg / cm³.

[0286] EX4. The aerosol - generating system according to Example EX3, wherein the initial density of the strip of the aerosol - generating substrate is less than 150 mg / cm³.

[0287] EX5. The aerosol - generating system according to Example EX3, wherein the initial density of the strip of the aerosol - generating substrate is between 75 mg / cm³ and 300 mg / cm³.

[0288] EX6. The aerosol - generating system according to any one of the preceding examples, wherein the final density of the strip of the aerosol - generating substrate is at least twice the initial density.

[0289] EX7. The aerosol - generating system according to any one of the preceding examples, wherein the final density is at least 300 mg / cm³.

[0290] EX8. The aerosol - generating system according to any one of the preceding examples, wherein the final density is between 150 mg / cm³ and 500 mg / cm³.

[0291] EX9. The aerosol - generating system according to any one of the preceding examples, wherein the strip of the aerosol - generating substrate has an initial cross - sectional area before the aerosol - generating article is inserted into the aerosol - generating device, and wherein the cross - section of the heating chamber of the aerosol - generating device is configured such that when the strip of the aerosol - generating substrate is inserted into the heating chamber, the strip of the aerosol - generating substrate is compressed to a final cross - sectional area, and the initial cross - sectional area is at least 1.1 times the final cross - sectional area.

[0292] EX10. The aerosol - generating system according to Example EX9, wherein the initial cross - sectional area of the strip of the aerosol - generating substrate is at least 28 square millimeters.

[0293] EX11. The aerosol - generating system according to Example EX10, wherein the initial cross - sectional area of the strip of the aerosol - generating substrate is between 28 square millimeters and 50 square millimeters.

[0294] EX12. An aerosol-generating system according to any one of Examples EX9 to EX11, wherein the initial cross-sectional area is at least twice the final cross-sectional area.

[0295] EX13. An aerosol-generating system according to any one of Examples EX7 to EX12, wherein the final cross-sectional area is less than 30 square millimeters.

[0296] EX14. The aerosol-generating system according to Example EX13, wherein the final cross-sectional area is between 10 square millimeters and 30 square millimeters.

[0297] EX15. An aerosol-generating system according to any one of the preceding examples, wherein the strip of aerosol-generating substrate has an initial maximum diameter before the aerosol-generating article is inserted into the aerosol-generating device, and wherein the cross-section of the heating chamber of the aerosol-generating device is configured such that when the strip of aerosol-generating substrate is inserted into the heating chamber, the strip of aerosol-generating substrate is compressed such that the strip of aerosol-generating substrate has a final maximum diameter after compression, the final maximum diameter being at least 1.1 times the initial maximum diameter.

[0298] EX16. The aerosol-generating system according to Example EX15, wherein the

[0299] EX17. An aerosol-generating article according to any one of the preceding examples, wherein the strip of aerosol-generating substrate is adapted to be compressible to a final density of at least 300 mg / cubic centimeter.

[0300] EX18. An aerosol-generating system according to any one of the preceding examples, wherein the initial maximum diameter of the strip of aerosol-generating substrate is less than 8.5 millimeters.

[0301] EX19. The aerosol-generating system according to Example EX18, wherein the initial maximum diameter of the strip of aerosol-generating substrate is between 6 millimeters and 8.5 millimeters.

[0302] EX20. An aerosol-generating system according to any one of Examples EX15 to EX19, wherein the final maximum diameter of the strip of aerosol-generating substrate can be at least 1.25 times the initial maximum diameter.

[0303] EX21. An aerosol-generating system according to any one of Examples EX15 to EX20, wherein the final maximum diameter of the strip of aerosol-generating substrate is at least 8 millimeters.

[0304] EX22. The aerosol-generating system according to Example EX21, wherein the final maximum diameter of the strip of aerosol-generating substrate is between 8 millimeters and 10.5 millimeters.

[0305] EX23. An aerosol-generating system according to any of the preceding examples, wherein the strip of the aerosol-generating substrate has a substantially circular cross-section before the aerosol-generating article is inserted into the aerosol-generating device.

[0306] EX24. An aerosol-generating system according to any of the preceding examples, wherein the strip of the aerosol-generating substrate has a substantially rectangular cross-section after the aerosol-generating article is inserted into the aerosol-generating device.

[0307] EX25. The aerosol-generating system according to example EX24, wherein the width of the rectangle is preferably at least twice the height of the rectangle.

[0308] EX26. An aerosol-generating system according to any of the preceding examples, wherein the aerosol-generating substrate comprises an aerosol-forming agent.

[0309] EX27. An aerosol-generating system according to any of the preceding examples, wherein the aerosol-generating substrate comprises at least 40% by weight of an aerosol-forming agent.

[0310] EX28. The aerosol-generating system according to any of the preceding claims, wherein the aerosol-generating substrate is substantially free of tobacco.

[0311] EX29. The aerosol-generating system according to any one of examples EX1 to EX27, wherein the aerosol-generating substrate comprises homogenized tobacco material.

[0312] EX30. The aerosol-generating system according to any one of examples EX1 to EX27, wherein the aerosol-generating substrate comprises cut filler.

[0313] EX31. The aerosol-generating system according to any one of examples EX1 to EX28, wherein the aerosol-generating substrate comprises an aerosol-generating film, the aerosol-generating film comprising a cellulose-based film-forming agent, nicotine and an aerosol-forming agent.

[0314] EX32. The aerosol-generating system according to any one of examples EX1 to EX28, wherein the aerosol-generating substrate comprises a gel composition, the gel composition comprising nicotine, at least one gelling agent and an aerosol-forming agent.

[0315] EX33. The aerosol-generating system according to example EX32, wherein the gel composition is loaded onto a porous medium.

[0316] EX34. An aerosol-generating system according to any of the preceding examples, wherein the aerosol-generating article further comprises one or more elongate sensor elements within the strip of the aerosol-generating substrate.

[0317] EX35. The aerosol-generating system according to any one of the preceding examples, wherein the downstream section of the aerosol-generating article comprises a compressible hollow tubular support element.

[0318] EX36. The aerosol-generating system according to example EX35, wherein the hollow tubular support element comprises an outer peripheral wall having a density of less than 140 mg / cm³.

[0319] EX37. The aerosol-generating system according to example EX35 or EX36, wherein the downstream section further comprises a hollow tubular cooling element.

[0320] EX38. The aerosol-generating system according to example EX37, wherein the aerosol-generating article further comprises a ventilation zone at a position along the hollow tubular cooling element.

[0321] EX39. The aerosol-generating system according to any one of examples EX35 to EX38, wherein the downstream section further comprises a downstream filter segment.

[0322] EX40. The aerosol-generating system according to any one of the preceding examples, wherein the aerosol-generating article further comprises a compressible upstream element located upstream of the strip of the aerosol-generating substrate.

[0323] EX41. The aerosol-generating system according to example EX40, wherein the compressible upstream element has a density of less than 140 mg / cm³.

[0324] EX42. The aerosol-generating system according to example EX40 or EX41, wherein the upstream element is adapted to be compressible to a final density that is at least 1.5 times the initial density.

[0325] EX43. The aerosol-generating system according to any one of examples EX40 to EX42, wherein the upstream element is adapted to be compressible to a final density of at least 140 mg / cm³.

[0326] EX44. The aerosol-generating system according to any one of examples EX40 to EX43, wherein the upstream element is formed of a fibrous filter material.

[0327] EX45. The aerosol-generating system according to example EX44, wherein the fibrous filter material has a denier per filament of less than 3.

[0328] EX46. The aerosol-generating system according to example EX44 or EX45, wherein the fibrous filter material has a total denier of less than 30,000.

[0329] EX47. An aerosol - generating system according to any one of Examples EX44 to EX46, wherein the fibrous filter material comprises a filter plasticizer, and wherein the amount of the filter plasticizer in the upstream element is less than 4% by weight of the upstream element.

[0330] EX48. An aerosol - generating system according to any one of Examples EX40 to EX47, wherein the upstream element has a draw resistance of less than 25 mm H2O.

[0331] EX49. An aerosol - generating system according to any one of Examples EX40 to EX48, wherein the upstream element has a length between 3 mm and 7 mm.

[0332] EX50. An aerosol - generating system according to any one of Examples EX40 to EX49, wherein the upstream element is defined by a wrapper.

[0333] EX51. The aerosol - generating system according to Example EX50, wherein the wrapper has a thickness of less than 40 microns.

[0334] EX52. The aerosol - generating system according to Example EX50 or EX51, wherein the wrapper has a basis weight of less than 25 g / m².

[0335] EX53. The aerosol - generating system according to any one of the preceding examples, wherein the overall RTD of the aerosol - generating article is at least 25 mm H2O.

[0336] EX54. The aerosol - generating system according to any one of the preceding examples, wherein the aerosol - generating article further comprises an outer wrapper.

[0337] EX55. The aerosol - generating article according to Example EX54, wherein the outer wrapper has a thickness of less than 65 microns.

[0338] EX56. The aerosol - generating article according to Example EX54 or EX55, wherein the outer wrapper has a basis weight of less than 45 g / m².

[0339] EX57. The aerosol - generating system according to any one of the preceding examples, wherein the heating chamber comprises a pair of opposing flat surfaces configured to receive a strip of the aerosol - generating substrate therebetween; and a heater element disposed on or near at least one of the pair of opposing flat surfaces.

[0340] EX58. The aerosol - generating system according to Example EX57, wherein the pair of opposing flat surfaces of the heating chamber are substantially parallel to each other.

[0341] EX59. An aerosol - generating system according to example EX57 or EX58, wherein an average spacing between a pair of opposing flat surfaces of the heating chamber is less than 5 millimeters.

[0342] EX60. An aerosol - generating system according to any one of examples EX57 to EX59, wherein an average spacing between a pair of opposing surfaces of the heating chamber is at least 1 millimeter less than a maximum diameter of a strip of the aerosol - generating substrate before the aerosol - generating article is inserted into the aerosol - generating device.

[0343] EX61. An aerosol - generating system according to any one of examples EX57 to EX60, wherein a ratio of an initial diameter of a strip of the aerosol - generating substrate to a spacing between a pair of opposing surfaces of the heating chamber is at least 1.5.

[0344] EX62. An aerosol - generating system according to any one of examples EX57 to EX61, wherein a cross - section of the heating chamber is configured such that when a strip of the aerosol - generating substrate is inserted into the heating chamber, the strip of the aerosol - generating substrate and the upstream element are compressed.

[0345] EX63. An aerosol - generating system according to example EX62, wherein a cross - sectional area of the heating chamber is less than an initial cross - sectional area of a strip of the aerosol - generating substrate.

[0346] EX64. An aerosol - generating system according to any one of the foregoing examples, wherein the heating chamber includes a funnel - shaped portion at the open downstream end, the funnel - shaped portion having a cross - sectional area that gradually decreases from the downstream end towards the upstream end.

[0347] EX65. An aerosol - generating system according to any one of the foregoing examples, wherein the heating chamber includes a pair of movable walls, wherein at least one of the movable walls includes a heater element on or near its inner surface, and wherein the movable walls are adapted such that they can move relative to each other between an open position and a closed position.

[0348] EX66. An aerosol - generating system according to any one of the foregoing examples, wherein the heater assembly includes an induction heating assembly. BRIEF DESCRIPTION OF THE DRAWINGS

[0349] The present invention will be further described below in conjunction with the drawings, in which:

[0350] Figure 1 A schematic side - view perspective view of a first aerosol - generating article for use in an aerosol - generating system according to the present invention is shown;

[0351] Figure 2Shows a schematic side cross-sectional view of a first aerosol-generating article for use in an aerosol-generating system according to the present invention;

[0352] Figure 3 Shows a schematic side cross-sectional view of an aerosol-generating device for use in an aerosol-generating article system according to the present invention;

[0353] Figure 4 Shows according to a first embodiment Figure 1 A schematic diagram of the compression of a strip of the aerosol-generating substrate of the aerosol-generating article when it is inserted into the heating chamber of the aerosol-generating device; and

[0354] Figure 5 Shows according to a second embodiment Figure 1 A schematic diagram of the compression of a strip of the aerosol-generating substrate of the aerosol-generating article when it is inserted into the heating chamber of the aerosol-generating device. Detailed Description

[0355] Figure 1 The aerosol-generating article 10 shown in includes a strip 12 of aerosol-generating substrate and a downstream section 14 at a position downstream of the strip 12 of aerosol-generating substrate. Thus, the aerosol-generating article 10 extends from an upstream end or distal end 16 that substantially coincides with the upstream end of the strip 12 to a downstream end or mouth end 18 that coincides with the downstream end of the downstream section 14. The downstream section 14 includes a hollow tubular element 20 and a mouthpiece element 50.

[0356] The aerosol-generating article 10 has an overall length of approximately 45 millimeters and an outer diameter of approximately 7.1 millimeters.

[0357] The strip 12 of aerosol-generating substrate has a length of 12 millimeters and includes shredded tobacco material. The strip 12 of aerosol-generating substrate includes approximately 70 milligrams of shredded tobacco material, and the shredded tobacco material includes 13 wt% to 16 wt% of glycerol. The volumetric density of the strip 12 of aerosol-generating substrate is approximately 150 mg / cubic centimeter. The strip 12 of aerosol-generating substrate is cylindrical and has a circular cross-section with an outer diameter of 7.1 millimeters. Since the cross-section is circular, the maximum diameter of the strip of aerosol-generating substrate is also 7.1 millimeters. The initial cross-sectional area of the strip of aerosol-generating substrate is approximately 39.5 square millimeters.

[0358] The strip 12 of aerosol-generating substrate is individually packaged by a rod wrapper (not shown).

[0359] The hollow tubular element 20 is located immediately downstream of the strip 12 of aerosol-generating substrate, and the hollow tubular element 20 is longitudinally aligned with the strip 12. The upstream end of the hollow tubular element 20 abuts the downstream end of the strip 12 of aerosol-generating substrate.

[0360] The hollow tubular element 20 defines a hollow section of the aerosol-generating article 10. The hollow tubular element substantially does not affect the overall RTD of the aerosol-generating article. More specifically, the RTD of the hollow tubular element 20 is about 0 mmH2O.

[0361] As Figure 2 shown, the hollow tubular element 20 is provided in the form of a hollow cylindrical tube made of cardboard. The hollow tubular element 20 defines a lumen 22 that extends from the upstream end of the hollow tubular element 20 to the downstream end of the hollow tubular element 20. The lumen 22 is substantially empty, and thus substantially unrestricted air flow is achieved along the lumen 22. The hollow tubular element 20 substantially does not affect the overall RTD of the aerosol-generating article 10.

[0362] The hollow tubular element 20 has a length of about 21 millimeters, an outer diameter of about 7.1 millimeters, and an inner diameter of about 6.7 millimeters. Thus, the thickness of the outer peripheral wall of the hollow tubular element 20 is about 0.25 millimeters.

[0363] The aerosol-generating article 10 includes a ventilation zone 30 disposed at a position along the hollow tubular element 20. More specifically, the ventilation zone 30 is provided at about 16 millimeters from the downstream end 18 of the article 10. The ventilation zone 30 is provided about 12 mm downstream of the downstream end of the strip 12 of the aerosol-forming substrate. The ventilation zone 30 is provided about 9 millimeters upstream of the upstream end of the mouthpiece element 50. The ventilation zone 30 includes a row of circumferential openings or perforations that define the hollow tubular element 20. The perforations of the ventilation zone 30 extend through the wall of the hollow tubular element 20 to allow fluid to enter the lumen 22 from the outside of the article 10. The ventilation level of the aerosol-generating article 10 is about 16%.

[0364] The aerosol-generating article 10 further includes an upstream section 40 at a position upstream of the strip 12 of the aerosol-forming substrate. Thus, the aerosol-generating article 10 extends from a distal end 16 that substantially coincides with the upstream end of the upstream section 40 to a mouth end or downstream end 18 that substantially coincides with the downstream end of the downstream section 14.

[0365] The upstream section 40 includes an upstream element 42 immediately upstream of the strip 12 of the aerosol-forming substrate, and the upstream element 42 is longitudinally aligned with the strip 12. The downstream end of the upstream element 42 abuts the upstream end of the strip 12 of the aerosol-forming substrate. The upstream element 42 is provided in the form of a solid cylindrical rod of cellulose acetate tow. The upstream element 42 has a length of about 5 millimeters. The outer diameter of the upstream element 42 is about 7.1 millimeters.

[0366] The mouthpiece element 50 extends from the downstream end of the hollow tubular element 20 to the downstream end or mouth end of the aerosol-generating article 10. The mouthpiece element 50 has a length of about 7 millimeters. The outer diameter of the mouthpiece element 50 is about 7.1 millimeters. The mouthpiece element 50 includes a low-density cellulose acetate filter segment. The RTD of the mouthpiece element 50 is about 8 mmH2O. The mouthpiece element 50 can be individually packaged by a rod pack (not shown).

[0367] As Figure 1 and 2 shown in, the article 10 includes an upstream wrapper 44 that defines an upstream element 42, a strip 12 of aerosol-generating substrate, and a hollow tubular element 20. The ventilation zone 30 may also include a row of circumferential perforations provided on the upstream wrapper 44. The perforations of the upstream wrapper 44 overlap the perforations provided on the hollow tubular element 20. Thus, the upstream wrapper 44 overlies the perforations of the ventilation zone 30 provided on the hollow tubular element 20.

[0368] The article 10 further includes a tipping wrapper 52 that defines the hollow tubular element 20 and the mouthpiece element 50. The tipping wrapper 52 overlies the portion of the upstream wrapper 44 that overlies the hollow tubular element 20. In this way, the tipping wrapper 52 effectively connects the mouthpiece element 50 to the rest of the components of the article 10. The width of the tipping wrapper 52 is about 26 mm. Additionally, the ventilation zone 30 may include a row of circumferential perforations provided on the tipping wrapper 52. The perforations of the tipping wrapper 52 overlap the perforations provided on the hollow tubular element 20 and the upstream wrapper 44. Thus, the tipping wrapper 52 overlies the perforations of the ventilation zone 30 provided on the hollow tubular element 20 and the upstream wrapper 44.

[0369] Figure 3 Shown is an aerosol-generating device for use in conjunction with the aerosol-generating article 10 as Figure 1 and Figure 2 shown in. The aerosol-generating device is shown before insertion of the aerosol-generating article.

[0370] Figure 3 The aerosol-generating device 100 shown in includes a housing (or body) 102 that extends between a mouth end 104 and a distal end (not shown). The housing 102 includes an outer peripheral wall 106. The outer peripheral wall 106 defines an elongated heating chamber 108 for receiving the aerosol-generating article 10. The heating chamber 108 is defined by a closed distal end and an open mouth end. The mouth end 104 of the heating chamber 108 is located at the mouth end of the aerosol-generating device 100. The aerosol-generating article 10 is configured to be received through the mouth end 104 of the heating chamber 108 and is configured to abut the closed end of the heating chamber 108.

[0371] The heating chamber 108 has a substantially rectangular cross-section which defines a pair of opposing flat walls 109 that are substantially parallel to each other and spaced apart from each other by approximately 2 millimeters. During use, the strip 12 of the aerosol-generating substrate of the aerosol-generating article 10 will be inserted between the opposing flat walls 109. Each of the opposing flat walls 109 is provided with a planar heating element (not shown) in the form of a resistive heating element. Thus, the heating chamber provides a heater assembly including a pair of opposing flat heater elements or heater plates. During use, when the strip 12 of the aerosol-generating substrate is inserted between the opposing flat walls 109, the aerosol-generating substrate will thus be heated from the top and bottom by the opposing heater elements.

[0372] The spacing between the opposing flat walls 109 of the heating chamber 108 is approximately 5 millimeters less than the diameter of the strip 12 of the aerosol-generating substrate before the aerosol-generating article 10 is inserted into the aerosol-generating device 100. Thus, the strip 12 of the aerosol-generating substrate is significantly compressed when it is inserted into the heating chamber 108. This is described in more detail below.

[0373] The device airflow channel 105 is defined within the outer peripheral wall 106. The airflow channel 105 extends between an inlet 107 located at the mouth end of the aerosol-generating device 100 and the closed end of the heating chamber. Air can enter the aerosol-generating substrate 12 via an orifice (not shown) provided at the closed end of the device cavity to ensure fluid communication between the airflow channel 105 and the aerosol-generating substrate 12.

[0374] The aerosol-generating device 100 also includes a power source (not shown) for supplying power to the heater element. A controller (not shown) is also provided to control this power supply to the heater element. The heater element is configured to controllably heat the aerosol-generating article 10 during use when the aerosol-generating article 10 is received within the device 100. The heater is preferably arranged to externally heat the aerosol-generating substrate 12 to achieve optimal aerosol generation. The ventilation area 30 is arranged to be exposed when the aerosol-generating article 10 is received within the aerosol-generating device 100.

[0375] In order to insert the aerosol-generating article 10 into the aerosol-generating device 100, the strip 12 of the aerosol-generating substrate must be compressed and flattened such that the cross-sectional dimensions of the strip 12 of the aerosol-generating substrate substantially match the cross-sectional dimensions of the heating chamber 108 of the aerosol-generating device. In particular, the strip of the aerosol-generating substrate having an initial diameter of 7.1 millimeters must be compressed such that it is flattened in one dimension to a thickness that substantially matches the spacing between the opposing flat walls 109 of the heating chamber 108, which spacing is approximately 2 millimeters. The upstream element 23 must also be compressed to the same cross-sectional dimensions.

[0376] To insert the upstream end of the strip 12 of the aerosol - forming substrate into the heating chamber 108, the consumer may need to squeeze or pinch the upstream end to flatten it. Once the end of the aerosol - generating article 10 is in place within the heating chamber 108, the aerosol - generating article 10 can then be pushed in the upstream direction to insert the strip of the aerosol - forming substrate as far as possible into the heating chamber 108. When the aerosol - generating article 10 is pushed inwards, the remainder of the strip 12 of the aerosol - forming substrate will compress and flatten.

[0377] Once the strip 12 of the aerosol - forming substrate is fully received within the heating chamber 108, it has a rectangular cross - section with a height of 2 millimeters and a width of approximately 9 millimeters. This width corresponds to the final maximum diameter of the strip 12 of the aerosol - forming substrate. Thus, the final maximum diameter is approximately 1.25 times the initial maximum diameter. After compressing the strip 12 of the aerosol - forming substrate, it has an increased density of approximately 315 mg / cubic centimeter. Thus, the final density of the aerosol - forming substrate is more than twice the initial density. The cross - sectional area has been reduced to approximately 18 square millimeters. Thus, the initial cross - sectional area is more than twice the final cross - sectional area.

[0378] Compressing the strip 12 of the aerosol - forming substrate into a rectangular form increases the contact area between the aerosol - forming substrate and the heater element and also reduces the distance over which heat needs to be transferred in order to effectively heat all of the aerosol - forming substrate within the strip. Thus, the aerosol - forming substrate can be heated very effectively, minimizing waste of the tobacco material.

[0379] Insertion of the strip 12 of the aerosol - forming substrate into the heating chamber 108 can be facilitated by making the heating chamber 108 adapted to include a funnel - shaped portion at the downstream end, the funnel - shaped portion having a gradually decreasing cross - sectional area to assist in gradually compressing the strip of the aerosol - forming substrate. This is not shown in Figure 3 but the use of the funnel - shaped portion is schematically shown in Figure 4

[0380] Figure 4 A schematic view of the insertion of the strip 12 of the aerosol - forming substrate into a heating chamber 208 is shown, the heating chamber including a funnel - shaped portion 210 at the downstream end. The downstream end of the funnel - shaped portion 210 has a cross - sectional area significantly larger than the cross - sectional area of the strip of the aerosol - forming substrate, and the cross - sectional area and shape change gradually towards the upstream end such that at the upstream end of the funnel - shaped portion, the cross - sectional area substantially matches the cross - sectional area of the remainder of the heating chamber 208. As described above, the heating element is disposed on the flat opposing walls 209 provided inside the heating chamber. In Figure 4 for simplicity, only the strip 12 of the aerosol - forming substrate is shown. The downstream section of the aerosol - generating article will remain outside the heating chamber. Figure 4The illustration on the left shows the aerosol - generating system before the aerosol - generating article is inserted into the aerosol - generating device, and Figure 4 the illustration on the right shows the aerosol - generating system after the aerosol - generating article has been inserted into the aerosol - generating device.

[0381] As Figure 4 shown on the left of, the strip 12 of the aerosol - generating substrate has an initial diameter and cross - sectional area that are significantly larger than the diameter and cross - sectional area of the heating chamber 208. Thus, as described above, the strip 12 of the aerosol - generating substrate must be compressed when it is inserted into the heating chamber 208. Once in place in the heating chamber 208, the strip of the aerosol - generating substrate is clamped between the opposing flat walls 209 and has a substantially rectangular cross - section. Thus, the strip of the aerosol - generating substrate has been significantly flattened and the density of the aerosol - generating substrate has increased. The largest of the rectangular surfaces of the compressed strip 12 of the aerosol - generating substrate contacts the opposing flat walls, such that the strip of the aerosol - generating substrate is heated from both the top and bottom sides during heating. Thus, the strip of the aerosol - generating substrate has been significantly flattened and the density of the aerosol - generating substrate has increased.

[0382] In other embodiments, as described above, the heating chamber may include a movable wall. In Figure 5 the use of such a heating chamber is shown.

[0383] Figure 5 shows a schematic view of inserting the strip 12 of the aerosol - generating substrate into a heating chamber 308 that includes a pair of flat movable walls 310 that are joined at one end and pivotable relative to each other about a hinge line 312. The movable walls 310 pivot about the hinge line 312 between an open position shown on the left of Figure 5 and a closed position shown on the right of Figure 5 . In the open position, the movable walls 310 are positioned apart from each other and the strip 12 of the aerosol - generating substrate can be easily inserted into the space between the walls 310. To close the heating chamber, the movable walls 310 are moved towards each other back to the closed position. When the movable walls 310 are pressed together, the strip of the aerosol - generating substrate is compressed and flattened such that in the closed position of the movable walls 310, the strip of the aerosol - generating substrate has a flattened form with a substantially rectangular cross - section. The flattened strip of the aerosol - generating substrate is clamped between the movable walls, where its largest rectangular surface contacts the movable walls. Each movable wall is provided with a heater element on its surface such that the strip of the aerosol - generating substrate is heated from both the top and bottom sides during heating.

[0384] In Figure 4 for simplicity, only the strip 12 of the aerosol - generating substrate is shown. The downstream section of the aerosol - generating article will remain outside the heating chamber.

[0385] For the purposes of this specification and the appended claims, unless otherwise indicated, all numbers expressing quantities, amounts, percentages, etc. are to be understood as being modified in all instances by the term "about". Also, all ranges include the disclosed maximum and minimum points and any intermediate ranges therebetween that may be specifically enumerated or may not be enumerated herein. Thus, herein, a number A is understood to be A ± 10%. In this document, a number A may be considered to include values within the general standard error of measurement of the property modified by the number A. In certain instances used in the appended claims, the number A may deviate from the percentage recited above, provided that the amount by which A deviates does not materially affect the basic and novel characteristics of the claimed invention. Also, all ranges include the disclosed maximum and minimum points and any intermediate ranges therebetween that may be specifically enumerated or may not be enumerated herein.

Claims

1. An aerosol - generating system, the aerosol - generating system comprising: An aerosol - generating article for generating an inhalable aerosol upon heating, the aerosol - generating article extending from a mouth end to a distal end and comprising: A strip of aerosol - generating substrate; and A downstream section located downstream of the strip of aerosol - generating substrate, the downstream section extending from the downstream end of the strip of aerosol - generating substrate to the mouth end of the aerosol - generating article; and An aerosol - generating device, the aerosol - generating device comprising: A body defining a heating chamber for removably receiving at least a portion of the strip of aerosol - generating substrate of the aerosol - generating article when the aerosol - generating article is inserted into the aerosol - generating device; and A heater assembly disposed along at least a portion of the heating chamber for heating the strip of aerosol - generating substrate when the aerosol - generating article is received within the aerosol - generating device, Wherein the strip of aerosol - generating substrate has an initial density of less than 250 mg per cubic centimeter before the aerosol - generating article is inserted into the aerosol - generating device, and wherein the cross - section of the heating chamber of the aerosol - generating device is configured such that when the strip of aerosol - generating substrate is inserted into the heating chamber, the strip of aerosol - generating substrate is compressed to a final density that is at least 1.5 times the initial density.

2. The aerosol - generating system according to claim 1, wherein the initial density of the strip of aerosol - generating substrate is less than 200 mg per cubic centimeter.

3. The aerosol - generating system according to claim 1 or 2, wherein the final density is at least twice the initial density.

4. The aerosol - generating system according to any one of the preceding claims, wherein the final density is at least 300 mg per cubic centimeter.

5. An aerosol - generating system, the aerosol - generating system comprising: An aerosol - generating article for generating an inhalable aerosol upon heating, the aerosol - generating article extending from a mouth end to a distal end and comprising: A strip of aerosol - generating substrate; and A downstream section located downstream of the strip of aerosol - generating substrate, the downstream section extending from the downstream end of the strip of aerosol - generating substrate to the mouth end of the aerosol - generating article; and An aerosol - generating device, the aerosol - generating device comprising: A body defining a heating chamber for removably receiving at least a portion of the strip of aerosol - generating substrate of the aerosol - generating article when the aerosol - generating article is inserted into the aerosol - generating device; and A heater assembly for heating the strip of aerosol - generating substrate when the strip of aerosol - generating substrate is received within the heating chamber, Wherein the strip of aerosol - generating substrate has an initial density of less than 250 mg per cubic centimeter before the aerosol - generating article is inserted into the aerosol - generating device; The strip of the aerosol - forming substrate has an initial cross - sectional area before the aerosol - generating article is inserted into the aerosol - generating device, and the cross - section of the heating chamber of the aerosol - generating device is configured such that when the strip of the aerosol - forming substrate is inserted into the heating chamber, the strip of the aerosol - forming substrate is compressed to a final cross - sectional area, wherein the initial cross - sectional area is at least 1.5 times the final cross - sectional area.

6. The aerosol - generating system according to claim 5, wherein the initial cross - sectional area of the strip of the aerosol - forming substrate is at least 30 square millimeters.

7. The aerosol - generating system according to claim 5 or 6, wherein the initial cross - sectional area of the strip of the aerosol - forming substrate is at least twice the final cross - sectional area.

8. The aerosol - generating system according to any one of claims 5 to 7, wherein the final cross - sectional area is less than 22 square millimeters.

9. An aerosol - generating system, the aerosol - generating system comprising: An aerosol - generating article for generating an inhalable aerosol upon heating, the aerosol - generating article extending from a mouth - end to a distal end and comprising: A strip of aerosol - forming substrate; and A downstream section located downstream of the strip of the aerosol - forming substrate, the downstream section extending from the downstream end of the strip of the aerosol - forming substrate to the mouth - end of the aerosol - generating article; and An aerosol - generating device, the aerosol - generating device comprising: A body defining a heating chamber for removably receiving at least a portion of the strip of the aerosol - forming substrate of the aerosol - generating article when the aerosol - generating article is inserted into the aerosol - generating device; and A heater assembly for heating the strip of the aerosol - forming substrate when the strip of the aerosol - forming substrate is received within the heating chamber, wherein the strip of the aerosol - forming substrate has an initial density of less than 250 mg / cubic centimeter before the aerosol - generating article is inserted into the aerosol - generating device; wherein the strip of the aerosol - forming substrate has an initial maximum diameter before the aerosol - generating article is inserted into the aerosol - generating device, and the cross - section of the heating chamber of the aerosol - generating device is configured such that when the strip of the aerosol - forming substrate is inserted into the heating chamber, the strip of the aerosol - forming substrate is compressed such that the strip of the aerosol - forming substrate has a final maximum diameter after compression, the final maximum diameter being at least 1.5 times the initial maximum diameter.

10. The aerosol - generating system according to claim 9, wherein the final maximum diameter of the aerosol - forming substrate is at least 8 millimeters.

11. The aerosol - generating system according to any one of the preceding claims, wherein before the aerosol - generating article is inserted into the aerosol - generating device, the cross - section of the aerosol - forming substrate is substantially circular, and wherein after the aerosol - generating article is inserted into the aerosol - generating device, the cross - section of the aerosol - forming substrate is substantially rectangular.

12. The aerosol generating system according to claim 11, wherein after the aerosol generating article is inserted into the aerosol generating device, a cross-section of the aerosol generating substrate is substantially rectangular, and a width of the rectangle is at least twice a height of the rectangle.

13. The aerosol generating system according to any one of the preceding claims, wherein a draw resistance (RTD) of the aerosol generating article after the aerosol generating article is inserted into the aerosol generating device is not more than 10% higher than the RTD of the aerosol generating article before the aerosol generating article is inserted into the aerosol generating device.

14. The aerosol generating system according to any one of the preceding claims, wherein the heating chamber includes a pair of opposing flat surfaces configured to receive a strip of the aerosol generating substrate therebetween; and a heater element disposed on or near at least one of the pair of opposing flat surfaces.

15. The aerosol generating system according to any one of the preceding claims, wherein the heating chamber further includes a funnel-shaped portion at the downstream end, and a cross-sectional area of the funnel-shaped portion gradually decreases from the downstream end toward the upstream end.

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