Aerosol-forming substrate, aerosol-generating article, device and system

Abstract

An aerosol-forming substrate includes an aerosol-forming material for generating an aerosol. The aerosol-forming substrate has a base defined by an x dimension and a y dimension, and a height defined by a z dimension, where an airflow path is defined through the aerosol-forming substrate from one side of the aerosol-forming substrate to the other side of the aerosol-forming substrate in an x / y plane, and where a resistance to suction (RTD) of the substrate along the airflow path is less than (20) mm H2O. Preferably, the matrix includes at least one corrugated element, and the airflow path is defined by a longitudinally extending channel defined at least in part by the corrugated element.

Description

[0001] The present disclosure relates to an aerosol-forming substrate and an aerosol-generating article comprising the aerosol-forming substrate. The present disclosure also relates to an aerosol-generating device, and an aerosol-generating system comprising the aerosol-generating article and the aerosol-generating device.

[0002] A typical aerosol-generating system may include an aerosol-generating device and an aerosol-generating article. The aerosol-generating device may include a heating device, such as a heating element, and the aerosol-generating article may include an aerosol-forming substrate. In use, the heating element of the aerosol-generating device may heat the aerosol-forming substrate of the aerosol-generating article to release an aerosol from the aerosol-forming substrate. The user may inhale the aerosol.

[0003] A typical aerosol-generating article may look similar to a conventional cigarette. For example, such an aerosol-generating article may be a substantially cylindrical article comprising an aerosol-forming substrate and other components such as a mouthpiece filter element, all of which are wrapped in cigarette paper. The dimensions of a typical aerosol-generating article are generally similar to those of a conventional cigarette.

[0004] Studies have shown that in such typical aerosol-generating articles, a substantial portion of the rod of aerosol-forming substrate may not be sufficiently heated during use to form an aerosol. This is undesirable because this portion of the rod of aerosol-forming substrate affects the manufacturing and shipping costs of the aerosol-generating article, but does not affect the aerosol delivered to the end user. This may be the case regardless of the manner in which the aerosol-forming substrate is heated, for example, whether a resistive heater or an induction heater is used, and whether the rod of aerosol-forming substrate is heated internally or externally.

[0005] It is an object of the present invention to provide an aerosol-forming substrate and an aerosol-generating article comprising the substrate, wherein a major portion of the aerosol-forming substrate of the aerosol-generating article is heated sufficiently to form an aerosol during use.

[0006] According to the present disclosure, there may be provided an aerosol-forming substrate comprising an aerosol-forming material for generating an aerosol. The aerosol-forming substrate may have a base defined by an x dimension extending in the x direction and a y dimension extending in the y direction, and a height defined by a z dimension extending in the z direction.

[0007] According to the present disclosure, an aerosol-forming substrate can be provided, which includes an aerosol-forming material for generating an aerosol, wherein the aerosol-forming substrate is a planar aerosol-forming substrate having a base defined by a length extending in the x-direction, a width extending in the y-direction, and a height extending in the z-direction.

[0008] According to the present disclosure, an aerosol-forming substrate can be provided, which includes an aerosol-forming material for generating an aerosol, wherein the aerosol-forming substrate has a base defined by an x dimension and a y dimension, and a height defined by a z dimension, wherein an airflow path is defined as passing through the aerosol-forming substrate from one side of the aerosol-forming substrate to the other side of the aerosol-forming substrate in the x / y plane, wherein the resistance to draw (RTD) of the substrate along the airflow path is less than 20 mm H2O.

[0009] According to the present disclosure, an aerosol-forming substrate may be provided, comprising an aerosol-forming material for generating an aerosol, the aerosol-forming substrate comprising a substantially planar upper surface defined by a length extending in the x-direction and a width extending in the y-direction, and a substantially planar lower surface defined by a length extending in the x-direction and a width extending in the y-direction. The substantially planar upper surface and the substantially planar lower surface may be vertically spaced apart from each other by a height defined in the z-direction.

[0010] According to the present disclosure, there may be provided an aerosol-forming substrate comprising a first planar layer and a corrugated layer arranged on a surface of the first planar layer, at least one of the first planar layer and the corrugated layer comprising or consisting of an aerosol-forming material.

[0011] According to the present disclosure, an aerosol-forming substrate may be provided, comprising a first planar layer, a second planar layer, and a corrugated layer arranged between the first planar layer and the second planar layer, wherein at least one of the first planar layer, the second planar layer, and the corrugated layer comprises an aerosol-forming material or consists of an aerosol-forming material.

[0012] According to the present disclosure, there may be provided an aerosol-forming substrate comprising a first layer and a corrugated layer attached to a surface of the first layer by an adhesive, wherein the adhesive comprises or consists of an aerosol-forming material.

[0013] According to the present disclosure, an aerosol-forming substrate may be provided, comprising a first layer, a second layer, and an intermediate layer disposed between the first layer and the second layer, wherein the intermediate layer is attached to the first layer and / or the second layer by an adhesive, wherein the adhesive comprises or consists of an aerosol-forming material.

[0014] According to the present disclosure, an aerosol-forming substrate may be provided, comprising a first layer and a corrugated layer attached to a surface of the first layer, a plurality of longitudinally extending channels defined by the corrugations between the first layer and the second layer, wherein a porous element is located in at least one of the longitudinally extending channels.

[0015] According to the present disclosure, an aerosol-forming substrate may be provided, comprising a first layer and a corrugated layer attached to a surface of the first layer, a plurality of longitudinally extending channels being defined by the corrugations between the first layer and the corrugated layer, wherein the longitudinally extending channels are filled with a porous material, such as a porous aerosol-forming material.

[0016] According to the present disclosure, an aerosol-forming substrate may be provided, comprising a first layer, a second layer, and a corrugated layer disposed between the first layer and the second layer, wherein a plurality of longitudinally extending channels are defined by the corrugations between the first layer and the corrugated layer and between the corrugated layer and the second layer, wherein a porous element is located in at least one of the longitudinally extending channels.

[0017] According to the present disclosure, there may be provided an aerosol-forming substrate comprising a first layer and a corrugated layer attached to a surface of the first layer, a plurality of longitudinally extending channels being defined by the corrugations between the first layer and the corrugated layer, wherein one or more flavor-releasing components, such as components such as threads or capsules impregnated with or containing a flavor component, are located within at least one of the longitudinally extending channels.

[0018] According to the present disclosure, there may be provided an aerosol-forming substrate comprising a first layer, a second layer and a corrugated layer disposed between the first layer and the second layer, a plurality of longitudinally extending channels being defined by the corrugations between the first layer and the corrugated layer and between the corrugated layer and the second layer, wherein one or more flavor-releasing components, such as components such as threads or capsules impregnated with or containing a flavor component, are located within at least one of the longitudinally extending channels.

[0019] According to the present disclosure, there may be provided an aerosol-forming substrate comprising a first planar layer and a corrugated layer arranged on a surface of the first planar layer, at least one of the first planar layer and the corrugated layer comprising perforations or holes to allow air to flow through the first planar layer or the corrugated layer.

[0020] According to the present disclosure, an aerosol-forming substrate may be provided, comprising a first planar layer, a second planar layer, and a corrugated layer arranged between the first planar layer and the second planar layer, wherein at least one of the first planar layer, the second planar layer, and the corrugated layer comprises perforations or holes to allow air to flow through the first planar layer, the second planar layer, or the corrugated layer.

[0021] According to the present disclosure, an aerosol-forming substrate can be provided, which includes a first planar layer, a second planar layer and a third planar layer arranged between the first planar layer and the second planar layer. The aerosol-forming substrate also includes a first corrugated layer arranged between the first planar layer and the third planar layer, and a second corrugated layer arranged between the third planar layer and the second planar layer.

[0022] The aerosol-forming substrate according to the present disclosure is preferably a substantially flat substrate or a substantially planar substrate. Such substrates have a large base area relative to the volume of the substrate. Advantageously, a larger base area can provide a larger surface area for heating by the planar heater of the aerosol generating device. Advantageously, a smaller height can allow a smaller temperature gradient or temperature difference across the height of the substrate during heating. For example, when the base of the substrate contacts and is heated by the planar heater, if the interval or height between the base and the upper surface is smaller, there may be a smaller temperature difference between the base and the upper surface relative to the base. Advantageously, this can allow a larger proportion of the substrate to be heated to the temperature for releasing the aerosol while minimizing the risk of burning the hottest part of the substrate closest to the heater. Alternatively or in addition, this can reduce the time required to fully heat the substrate to release the aerosol.

[0023] An aerosol-forming substrate according to the present disclosure preferably has a width to length ratio of between 1 :1 and 20:1 , such as between 2:1 and 10:1 or between 3:1 and 5: 1. Preferably, the aerosol-forming substrate is a discrete planar aerosol-forming substrate.

[0024] An aerosol-forming substrate according to any disclosure herein may have an airflow path defined as passing through the aerosol-forming substrate in the x / y plane from one side of the aerosol-forming substrate to the other side of the aerosol-forming substrate. The aerosol-forming substrate preferably has a resistance to draw (RTD) of less than 20 mm HO, such as less than 10 mm HO, in the direction of the airflow path. Preferably, the aerosol-forming substrate has an RTD of less than 20 mm HO, such as less than 10 mm HO, in at least one direction in the x / y plane of the aerosol-forming substrate. An aerosol-forming substrate having a low resistance airflow path may allow for superior airflow management and allow the aerosol to be more efficiently extracted from the aerosol-forming substrate and directed to the user.

[0025] The aerosol-forming substrate may have an RTD in a direction perpendicular to the z-direction, the resistance to draw being less than 20 mm HO, for example less than 10 mm HO. The airflow path may be defined as passing through the aerosol-forming substrate along the x-direction from one side of the aerosol-forming substrate to the other side of the aerosol-forming substrate, such that the aerosol-forming substrate has an RTD in the x-direction of less than 20 mm HO, for example less than 10 mm HO. The airflow path may be defined as passing through the aerosol-forming substrate along the y-direction from one side of the aerosol-forming substrate to the other side of the aerosol-forming substrate, such that the aerosol-forming substrate has an RTD in the y-direction of less than 20 mm HO, for example less than 10 mm HO.

[0026] Particularly preferably, the RTD is less than 8 mm H2O, such as less than 6 mm H2O, such as less than 4 mm H2O, such as less than 2 mm H2O. Preferably, the RTD in the gas flow path through the substrate is close to zero mm H2O.

[0027] The RTD may be between 9.9 mm H2O and 0 mm H2O, such as between 8 mm H2O and 1 mm H2O, or between 6 mm H2O and 2 mm H2O, or between 5 mm H2O and 3 mm H2O.

[0028] Unless otherwise stated, resistance to draw (RTD) is measured in accordance with ISO 6565-2015. RTD refers to the pressure required to force air through the full length of a component, such as an aerosol-forming substrate. The terms "pressure drop" or "draw resistance" of a component or article may also refer to "resistance to draw." Such terms generally refer to measurements in accordance with ISO 6565-2015, which are typically conducted in a test at a temperature of about 22 degrees Celsius, a pressure of about 101 kPa (about 760 Torr), and a relative humidity of about 60%, with a volumetric flow rate of about 17.5 ml / s at the output or downstream end of the measuring component.

[0029] The airflow path through the substrate may be defined in terms of porosity (e.g., the percentage of the substrate that is free of aerosol-forming material). In this case, the porosity is the open porosity, thereby allowing an airflow path through the substrate. Thus, the aerosol-forming substrate may have an airflow path defined as passing through the aerosol-forming substrate in the x / y plane from one side of the aerosol-forming substrate to the other side of the aerosol-forming substrate, and the aerosol-forming substrate may have a porosity greater than 60%, for example, greater than 80%, in the direction of the airflow path. The porosity may be greater than 60%, for example, greater than 80%, in at least one direction in the x / y plane of the aerosol-forming substrate. The aerosol-forming substrate may have a porosity in a direction perpendicular to the z-direction, greater than 60%, for example, greater than 80%. For example, the airflow path may be defined as passing through the aerosol-forming substrate along the x-direction from one side of the aerosol-forming substrate to the other side of the aerosol-forming substrate, such that the aerosol-forming substrate has a porosity greater than 60%, for example, greater than 80%, in the x-direction. The aerosol-forming substrate may have an airflow path defined along the y-direction through the aerosol-forming substrate from one side of the aerosol-forming substrate to the other side of the aerosol-forming substrate, such that the aerosol-forming substrate has a porosity in the y-direction of greater than 60%, for example greater than 80%. The porosity of the airflow path may be defined by the ratio of the cross-sectional area of the material within the airflow path to the internal cross-sectional area of the airflow path.

[0030] Preferably, in the direction of the air flow path the porosity is between 81% and 99%, such as a porosity between 85% and 95%, such as between 88% and 92%, such as about 90%.

[0031] Matrix can comprise the upper layer that limits upper surface and the lower layer that limits lower surface, and wherein airflow path is limited to passing aerosol formation matrix between upper layer and lower layer.For example, matrix can comprise the upper layer that limits upper surface and the lower layer that limits lower surface, and wherein airflow path is limited to passing aerosol formation matrix between upper layer and lower layer from one side to opposite side.For example, matrix can comprise the upper layer that limits upper surface and the lower layer that limits lower surface, and wherein airflow path is limited to passing aerosol formation matrix between upper layer and lower layer from one side to opposite side in x / y plane.Preferably, a plurality of passages are limited to passing aerosol formation matrix between upper surface and lower surface.Passage preferably provides the low RTD airflow path through matrix.

[0032] The aerosol-forming substrate may comprise a separation layer positioned between the upper layer and the lower layer. For example, the separation layer may comprise one or more ribs or struts separating the upper layer from the lower layer, preferably wherein the ribs or struts extend in a direction defining the airflow path through the aerosol-forming substrate. Thus, the separation layer may define the distance between the upper layer and the lower layer.

[0033] Preferably, the aerosol-forming substrate comprises a corrugated portion, such as one or more corrugated elements. For example, the separating layer may comprise or consist of a corrugated element, such as a sheet of corrugated material. The aerosol-forming substrate may comprise an upper layer, a lower layer, and a separating layer positioned between the upper and lower layers, wherein the separating layer comprises one or more corrugated elements. The one or more corrugated elements preferably define a plurality of airflow channels extending through the aerosol-forming substrate. In some examples, the corrugated structure may be combined with a single planar layer.

[0034] The use of a corrugated structure in an aerosol-forming substrate can advantageously allow the production of an aerosol-forming substrate having a very low RTD while still being sufficiently rigid for the user to handle. Furthermore, the use of a corrugated structure can allow the production of a low-density, low-RTD aerosol-forming substrate using high-speed production methods similar to those used to produce corrugated cardboard.

[0035] The aerosol-forming substrate may comprise a plurality of corrugated elements. For example, two or more corrugated elements may be arranged in a vertical relationship with one another, for example, between an upper layer and a lower layer. A plurality of corrugated elements may be described as being vertically stacked. Two corrugated elements arranged in a vertical relationship have their x and y dimensions in a plane parallel to one another and to any upper or lower layer. For example, the aerosol-forming substrate may comprise an upper corrugated element arranged in contact with an upper layer and a lower corrugated element arranged in contact with a lower layer. More than two corrugated elements may be present. For example, the substrate may comprise at least one additional corrugated element disposed between the upper and lower corrugated elements.

[0036] The aerosol-forming substrate may comprise a plurality of corrugated elements, wherein two or more of the plurality of corrugated elements are arranged in a side-by-side relationship with each other between an upper layer and a lower layer. Air following an airflow path through the substrate may flow through a first side-by-side spaced apart corrugated element or a second side-by-side spaced apart corrugated element.

[0037] The aerosol-forming substrate may comprise a plurality of corrugated elements, wherein two or more of the plurality of corrugated elements are arranged in lateral end-to-end relationship with each other between an upper layer and a lower layer. Air following an airflow path through the substrate may flow through both the first end-to-end spaced corrugated elements or the second end-to-end spaced corrugated elements.

[0038] The aerosol-forming substrate may be defined as having a proximal end and a distal end. An airflow path may be defined through the substrate between the proximal end and the distal end. Advantageously, the airflow path may be defined by at least one corrugated element. For example, the ridges and valleys of the at least one corrugated element may be aligned substantially parallel to the direction of airflow, thereby forming an airflow path in that direction.

[0039] The aerosol-forming substrate may include a first corrugated element positioned at or toward a proximal end of the substrate, and a second corrugated element positioned at or toward a distal end of the substrate. For example, the first and second corrugated elements may be arranged in a lateral end-to-end relationship between an upper layer and a lower layer, with each corrugated element aligned substantially parallel to the direction of airflow. In this example, the airflow path extends through both the first and second corrugated elements.

[0040] The aerosol-forming substrate comprises an aerosol-forming material. Preferably, the aerosol-forming material forms at least a portion of the corrugated structure or corrugated element. The aerosol-forming material may be in the form of a sheet material that serves as one or more components of the corrugated structure or corrugated element. This allows for great flexibility in selecting different combinations of aerosol-forming materials. This may also allow for the selection of suitable non-aerosol-forming materials for other purposes, such as to improve the structure of the substrate. In some examples, the entire aerosol-forming substrate is formed from the aerosol-forming material.

[0041] Therefore, the aerosol-forming substrate may include an upper layer, a lower layer and an intermediate layer arranged between the upper layer and the lower layer, wherein the upper layer includes an aerosol-forming material or consists of an aerosol-forming material, for example, wherein the upper layer includes an aerosol-forming material or consists of an aerosol-forming material, and the lower layer and the intermediate layer do not include an aerosol-forming material.

[0042] Alternatively, the aerosol-forming substrate may comprise an upper layer, a lower layer and an intermediate layer arranged between the upper layer and the lower layer, wherein the lower layer comprises an aerosol-forming material or consists of an aerosol-forming material, for example, wherein the lower layer comprises an aerosol-forming material or consists of an aerosol-forming material, and the upper layer and the intermediate layer do not comprise an aerosol-forming material.

[0043] Alternatively, the aerosol-forming substrate may comprise an upper layer, a lower layer and an intermediate layer arranged between the upper layer and the lower layer, wherein the intermediate layer comprises an aerosol-forming material or consists of an aerosol-forming material, for example, wherein the intermediate layer comprises an aerosol-forming material or consists of an aerosol-forming material, and the upper layer and the lower layer do not comprise an aerosol-forming material.

[0044] Alternatively, the aerosol-forming substrate may include an upper layer, a lower layer, and an intermediate layer arranged between the upper layer and the lower layer, wherein the lower layer includes a first aerosol-forming material or consists of a first aerosol-forming material, and the upper layer includes a second aerosol-forming material or consists of a second aerosol-forming material, and the intermediate layer does not include an aerosol-forming material.

[0045] Alternatively, the aerosol-forming substrate may include an upper layer, a lower layer, and an intermediate layer arranged between the upper layer and the lower layer, wherein the lower layer includes a first aerosol-forming material or consists of a first aerosol-forming material, and the intermediate layer includes a second aerosol-forming material or consists of a second aerosol-forming material, and the lower layer does not include an aerosol-forming material.

[0046] Alternatively, the aerosol-forming substrate may include an upper layer, a lower layer, and an intermediate layer arranged between the upper layer and the lower layer, wherein the upper layer includes a first aerosol-forming material or consists of a first aerosol-forming material, and the intermediate layer includes a second aerosol-forming material or consists of a second aerosol-forming material, and the upper layer does not include an aerosol-forming material.

[0047] Alternatively, the aerosol-forming substrate may include an upper layer, a lower layer, and an intermediate layer arranged between the upper layer and the lower layer, wherein the upper layer includes a first aerosol-forming material or consists of a first aerosol-forming material, and the intermediate layer includes a second aerosol-forming material or consists of a second aerosol-forming material, and the lower layer includes a third aerosol-forming material or consists of a third aerosol-forming material.

[0048] The aerosol-forming substrate is preferably formed from a sheet of material. For example, each of the upper layer, lower layer and middle layer is preferably formed from a sheet of material. The sheet may be a sheet of aerosol-forming material, such as a sheet of homogenized tobacco material. The sheet may be a sheet of non-aerosol-forming material, such as a sheet of paper. The thickness of any sheet forming a part of the aerosol-forming substrate may be between 0.02 mm and 2 mm. For example, any sheet-forming portion of the aerosol-forming substrate may have a thickness between 0.05 mm and 1.5 mm, such as between 0.1 mm and 1 mm, such as between 0.2 mm and 0.8 mm, such as between 0.3 mm and 0.6 mm, such as between 0.4 mm and 0.5 mm.

[0049] In certain embodiments, a sheet of homogenised tobacco material for use in an aerosol-forming substrate as described herein may have a thickness between 10 μm and about 300 μm. In certain embodiments, a sheet of homogenised tobacco material for use in an aerosol-forming substrate as described herein may have a thickness between 10 μm and about 300 μm. 2 With about 300g / m 2 The weight between.

[0050] Preferably, the upper layer comprises or is formed from a planar sheet of material, the lower layer comprises or is formed from a planar sheet of material, and the middle layer comprises or is formed from a corrugated sheet of material. In this case, at least some of the airflow channels formed by the corrugations are at least partially defined by the aerosol-forming material. This allows aerosol generated by the aerosol-forming material to be easily entrained in the airflow path.

[0051] The aerosol-forming substrate may comprise a first aerosol-forming material and a second aerosol-forming material.The aerosol-forming substrate may comprise a third aerosol-forming material.

[0052] The first aerosol-forming material may be the same material as the second aerosol-forming material.The first aerosol-forming material may be the same material as the third aerosol-forming material, for example the first aerosol-forming material, the second aerosol-forming material and the third aerosol-forming material may all be the same aerosol-forming material.

[0053] The first aerosol-forming material may be different from the second aerosol-forming material, e.g., have a different composition than the second aerosol-forming material, e.g., have a different aerosol-former content, or a different flavor content, or a different nicotine content. The first aerosol-forming material may be different from the third aerosol-forming material, e.g., have a different composition than the third aerosol-forming material, e.g., have a different aerosol-former content, or a different flavor content, e.g., wherein the first aerosol-forming material, the second aerosol-forming material, and the third aerosol-forming material are all different materials.

[0054] The aerosol-forming material may be a homogenised tobacco material. For example, any of the first aerosol-forming material, the second aerosol-forming material or the third aerosol-forming material may be a homogenised tobacco material.

[0055] The aerosol-forming substrate may comprise an upper layer, a lower layer, and an intermediate layer disposed between the upper and lower layers, wherein the intermediate layer is fixed relative to at least one of the upper and lower layers by an adhesive (e.g., an adhesive comprising a gum such as guar gum). Optionally, the adhesive may be an aerosol-forming material. For example, the adhesive may be a homogenized tobacco slurry. The adhesive may be or may contain a flavoring and / or an aerosol-forming agent. Thus, it is possible to form an aerosol-forming substrate in which all component parts (including the adhesive) are formed from aerosol-forming materials.

[0056] In instances where the substrate comprises an intermediate layer, the intermediate layer may comprise or consist of corrugated elements.

[0057] Preferably, the airflow path is defined through the aerosol-forming substrate by a channel formed or defined by the longitudinally extending corrugations of the corrugated element. Optionally, a porous material may be located within the channel formed by the longitudinally extending corrugations. The porous material may include or consist of an aerosol-forming material. The porous material may contain a flavoring or an aerosol-forming agent. For example, the porous material may be impregnated with a liquid flavoring or a liquid aerosol-forming agent.

[0058] Flavoring agents can be located within the channels formed by the longitudinally extending corrugations to release flavor upon heating. For example, flavor threads and / or one or more flavor capsules can be located within the channels. The flavor capsules can be sacs containing liquid or gel flavoring agents, such as sacs configured to release their contents upon heating, or frangible capsules designed to be broken open by the user prior to use.

[0059] Preferably, the airflow path or the airflow path is defined as passing through the aerosol-forming substrate in the x / y plane from one side of the aerosol-forming substrate to the other side of the aerosol-forming substrate. The airflow path may pass through a filter or mesh or porous material, such as porous paper, e.g., tea bag material, included in the aerosol-forming substrate. The filter or mesh or porous material may be arranged transversely to the airflow path, e.g., across the proximal end or downstream end of the aerosol-forming substrate. Such a filter or mesh or porous material may advantageously act as a filter to prevent solid particles from being inhaled by the user without significantly increasing the RTD.

[0060] In this context, the term "porous" is used to mean sufficiently porous to allow aerosols formed from the aerosol-forming substrate to escape through the porous layer during use. Advantageously, the porous layer can protect the aerosol-forming substrate from one or both of physical damage and chemical contamination. Advantageously, the porous layer can also help prevent the transfer of aerosol-forming material from the aerosol-forming substrate to a user handling the aerosol-forming substrate.

[0061] The aerosol-forming substrate may comprise a substantially planar layer and a corrugated layer secured to a surface of the substantially planar layer such that the longitudinal channels formed by the longitudinally extending corrugations of the corrugated layer extend in the direction of the plane of the substantially planar layer.

[0062] The aerosol-forming substrate may comprise an upper layer, a lower layer, and an intermediate layer, wherein at least one of the upper layer and the lower layer comprises perforations or holes, such that at least a portion of the air can flow through the upper layer and / or the lower layer. Preferably, the aerosol-forming substrate comprises a proximal or oral end and a distal end. The perforations or holes may be located in a central portion of the aerosol-forming substrate, for example approximately midway between the proximal or oral end and the distal end. The intermediate layer may comprise or consist of a corrugated element or layer arranged between the upper and lower layers, such that the longitudinal channels formed by the longitudinally extending corrugations of the corrugated element or layer extend in the plane of the upper and lower layers. The intermediate layer may comprise perforations or holes, such that at least a portion of the air can flow through the intermediate layer in a direction perpendicular to the longitudinally extending channels. At least one of the upper layer, the lower layer, and the intermediate layer may be or comprise a mesh.

[0063] The aerosol-forming substrate may include an upper layer, a lower layer and an intermediate layer, and the intermediate layer may include a corrugated element or layer arranged between the upper layer and the lower layer or consist of the corrugated element or layer, so that the longitudinal channels formed by the longitudinally extending corrugations of the corrugated element or layer extend in the planar direction of the upper layer and the lower layer, and wherein the intermediate layer includes perforations or holes so that at least a portion of the air can flow through the intermediate layer in a direction perpendicular to the longitudinally extending channels.

[0064] The aerosol-forming substrate may comprise a proximal end and a distal end. The proximal end may be referred to as the mouth end. The longitudinal channels formed by the longitudinally extending corrugations of the corrugated element or layer may extend in a direction perpendicular to the direction defined between the proximal or mouth end and the distal end. In this case, it may be particularly advantageous for the corrugated portion of the corrugated element to include perforations or holes, so that at least a portion of the air can flow through the corrugated element in a direction perpendicular to its longitudinally extending channels.

[0065] The aerosol-forming substrate may comprise one or more sheets of aerosol-forming material, wherein a plurality of holes or recesses are defined in a surface of the aerosol-forming material, such as an upper surface or a lower surface. When the aerosol-forming material is heated, an aerosol is generated from gases and vapors that may be released at the surface of the aerosol-forming material. Gases and vapors may also be released between the heated surface of the aerosol-forming material and the heater. The gases released between the aerosol-forming material and the heater may form bubbles that reduce the efficiency of heat transfer between the heater and the material. The plurality of holes or recesses defined in the surface of the aerosol-forming material may advantageously facilitate the release of volatile components of the aerosol-forming material into an air flow over the surface of the aerosol-forming material. For example, such holes or recesses may provide a low-resistance path for gases and vapors formed by heating the aerosol-forming material to escape from the bulk of the material to the surface of the material. By increasing the number of low-resistance paths from the bulk of the material to the surface of the material, aerosol delivery may be improved, and substrate utilization efficiency may be improved.

[0066] The aerosol-forming substrate may comprise a lower layer of aerosol-forming material and a corrugated layer attached to the lower layer, for example a corrugated layer of aerosol-forming material, wherein a plurality of holes or recesses are defined in at least one of the lower layer of aerosol-forming material and the corrugated layer. The plurality of holes or recesses may be defined in an upper surface of the aerosol-forming substrate.

[0067] In some examples, at least a portion of the plurality of holes are blind holes that do not extend through the thickness of the aerosol-forming material in which the blind holes are defined. In some examples, at least a portion of the plurality of holes are through holes that extend through the thickness of the aerosol-forming material in which the through holes are defined.

[0068] The aerosol-forming substrate may comprise a corrugated element or layer, and the corrugations of the corrugated element or layer may be defined by a corrugation wavelength and a corrugation amplitude. The corrugation wavelength may be between 1 mm and 10 mm, for example, between 1.5 mm and 8 mm, for example, between 2 mm and 6 mm, for example, between 2.5 mm and 5 mm, for example, between 3 mm and 4 mm. The corrugation amplitude may be between 1 mm and 10 mm, for example, between 1.5 mm and 8 mm, for example, between 2 mm and 6 mm, for example, between 2.5 mm and 5 mm, for example, between 3 mm and 4 mm. The corrugation amplitude is the same as the thickness (e.g., in terms of the z dimension) of the corrugated element or layer.

[0069] The corrugations can be formed in many different corrugation profiles. For example, the corrugations can also be defined by a corrugation profile, wherein the corrugation profile is sinusoidal, or triangular, or rectangular, or trapezoidal, or annular, or parabolic.

[0070] In some examples, the aerosol-forming substrate may be formed as an extrudate of an aerosol-forming material having an upper surface, a lower surface, and a plurality of airflow channels defined through the aerosol-forming substrate between the upper and lower surfaces.

[0071] The aerosol-forming substrate may have a length (x dimension) that is approximately the same magnitude as its width (y dimension). Alternatively, the length (x dimension) may be greater in magnitude than the width (y dimension). For example, the length may be about 1.5 times the magnitude of the width, or about 2 times the magnitude of the width, or about 2.5 times the magnitude of the width, or about 3 times the magnitude of the width. The length (x dimension) may be greater than 3 times the magnitude of the width, for example greater than 4 times the magnitude of the width, for example greater than 5 times the magnitude of the width.

[0072] The aerosol-forming substrate may have a base. The base is preferably substantially planar. The base may define a substantially planar lower surface of the aerosol-forming substrate.

[0073] The aerosol-forming substrate may be in the form of a 3-dimensional shape that can be described as a cuboid or a rectangular prism.

[0074] The aerosol-forming substrate may have a length (x dimension) and a width (y dimension) of one or both of which is equal to or greater than 2 times the magnitude of the height (z dimension), for example 3 times, or 4 times or 5 times the height, optionally equal to or greater than 6 times the height, for example 10 times the height, or 15 times the height or 20 times the height.

[0075] The aerosol-forming substrate may have a base defined by a rectangular shape having a length and width forming a lower surface of the aerosol-forming substrate. The upper surface of the aerosol-forming substrate may be defined by a substantially identical rectangular shape spaced apart from the base by a height, for example wherein both the lower and upper surfaces are defined as planar surfaces lying on parallel planes spaced apart by a height.

[0076] The aerosol-forming substrate may have a ratio of the largest of its length (x dimension) and its width (y dimension) in magnitude to its height (z dimension) of between 3:1 and 25:1, for example between 4:1 and 20:1, for example between 4.2:1 and 10:1, for example between 4.5:1 and 8:1, for example wherein the ratio of length to width is between 4:1 and 20:1, for example between 4.2:1 and 10:1, for example between 4.5:1 and 8:1. Advantageously, the above ratios can provide a compromise between at least four factors: the base surface area available for heating, which can increase with the x and y dimensions; the temperature difference across the height of the substrate when heating is applied at one or both of the base and the upper surface, which can increase with the z dimension; the structural rigidity of the substrate or article, which can decrease with the x and y dimensions for a given z dimension and increase with the z dimension for a given x and y dimension for substrates having x and y dimensions greater than 4 times the z dimension; and the ability of the substrate to generate a sufficient amount of aerosol to satisfy a user, which can increase with the x, y, and z dimensions.

[0077] The aerosol-forming substrate may have a length (x dimension) of between 10 mm and 50 mm, for example between 12 mm and 30 mm, for example between 14 mm and 26 mm, for example between 16 mm and 24 mm, for example between 18 mm and 22 mm, for example about 18 mm, or about 19 mm, or about 20 mm, or about 21 mm, or about 22 mm.

[0078] The aerosol-forming substrate may have a width (y-dimension) of between 5 mm and 20 mm, for example between 8 mm and 18 mm, for example between 10 mm and 16 mm, for example between 11 mm and 15 mm, for example between 12 mm and 14 mm, for example about 13 mm.

[0079] The aerosol-forming substrate may have a height (z dimension) of between 1 mm and 10 mm, for example between 1.2 mm and 8 mm, for example between 1.4 mm and 7 mm, for example between 1.6 mm and 6 mm, for example between 1.7 mm and 5 mm, for example about 1.7 mm, or about 4.5 mm, or about 2 mm, or about 3 mm, or about 4 mm.

[0080] The aerosol-forming substrate may consist entirely of aerosol-forming material.

[0081] The aerosol-forming substrate may further comprise a porous layer covering at least one surface of the aerosol-forming substrate, for example at least the upper surface, or at least the lower surface, or at least both the upper and lower surfaces. The porous layer may cover at least an end surface of the aerosol-forming substrate, for example at least at least one airflow inlet or outlet of the aerosol-forming substrate. The porous layer may completely encapsulate the aerosol-forming substrate. The porous layer may be a porous paper or a porous mesh, such as a layer of tea bag material. The porous layer may protect the surface of the aerosol-forming substrate, or a user handling the aerosol-forming substrate, while allowing the passage of gaseous components released from the aerosol-forming substrate.

[0082] The aerosol-forming substrate may comprise nicotine. The nicotine may be present in the form of a tobacco material or in the form of a nicotine extract.

[0083] Preferably, the aerosol-forming substrate comprises or consists of a homogenised tobacco material, such as reconstituted tobacco material or cast leaf tobacco material.

[0084] The aerosol-forming substrate may comprise or consist of a solid aerosol-forming material. The aerosol-forming substrate may comprise a liquid aerosol-forming material, for example a liquid aerosol-forming material held within a porous substrate. The aerosol-forming substrate may comprise a gel aerosol-forming material.

[0085] The first portion of the aerosol-forming substrate may include a first aerosol-forming material, and the second portion of the aerosol-forming substrate may include a second aerosol-forming material different from the first aerosol-forming material. For example, the first aerosol-forming material may be a first homogenized tobacco material, and the second aerosol-forming material may be a second homogenized tobacco material having a different composition than the first homogenized tobacco material. The first homogenized tobacco material composition may differ from the second tobacco composition by having at least one difference selected from the group consisting of: a different aerosol-forming agent content, a different tobacco content, a different flavoring agent content, a different water content, and a different nicotine content.

[0086] The first aerosol-forming material may be a first homogenised tobacco material and the second aerosol-forming material may be a non-tobacco aerosol-forming material comprising an aerosol-forming agent such as glycerol or propylene glycol, preferably comprising a flavour component and or an active component such as nicotine.

[0087] Advantageously, a matrix comprising two or more different aerosol-forming materials may allow for combinations of aerosol-forming materials that might not otherwise be available. This may allow for, for example, combinations of flavorings that enhance the user experience.

[0088] The aerosol-forming materials, for example any one, two or all of the aerosol-forming materials in the aerosol-forming substrate, may comprise one or more organic materials such as tobacco. The aerosol-forming materials, for example any one, two or all of the aerosol-forming materials in the aerosol-forming substrate, may comprise one or more of herb leaves, tobacco leaves, shredded tobacco ribs, reconstituted tobacco, homogenized tobacco, extruded tobacco and expanded tobacco.

[0089] The aerosol-forming material, for example any one, two, or all of the aerosol-forming materials in the aerosol-forming matrix, may comprise one or more aerosol-forming agents. Suitable aerosol-forming agents are well known in the art and include, but are not limited to, one or more aerosol-forming agents selected from the group consisting of polyols, such as propylene glycol, polyethylene glycol, triethylene glycol, 1,3-butylene glycol, and glycerol; esters of polyols, such as glycerol mono-, di-, or triacetate; and aliphatic esters of mono-, di-, or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate. It may be particularly preferred for the aerosol-forming agent to be or include glycerol.

[0090] The aerosol-forming material, for example any one, two or all of the aerosol-forming materials in the aerosol-forming substrate, may comprise at least 1%, 2%, 5%, 10% or 15% by weight of an aerosol-forming agent. The aerosol-forming material may comprise greater than 15% by weight of an aerosol-forming agent, for example greater than 20%, or greater than 25%, or greater than 30%, or greater than 40% or greater than 50% by weight of an aerosol-forming agent.

[0091] The aerosol-forming material may contain less than or equal to 30% by weight of an aerosol-forming agent, less than or equal to 25% by weight of an aerosol-forming agent, or less than or equal to 20% by weight of an aerosol-forming agent. In other words, the aerosol-forming material may have an aerosol-forming agent content of less than or equal to 30% by weight, less than or equal to 25% by weight, or less than or equal to 20% by weight.

[0092] The aerosol-forming material may comprise between 1 wt% and 30 wt% aerosol-former, between 1 wt% and 25 wt% aerosol-former, or between 1 wt% and 20 wt% aerosol-former.

[0093] The aerosol-forming material may comprise between 5% and 30% by weight aerosol-former, between 5% and 25% by weight aerosol-former, or between 5% and 20% by weight aerosol-former.

[0094] The aerosol-forming material may comprise between 10% and 30% by weight aerosol-former, between 10% and 25% by weight aerosol-former, or between 10% and 20% by weight aerosol-former.

[0095] The aerosol-forming material may comprise between 15% and 30% by weight aerosol-former, between 15% and 25% by weight aerosol-former, or between 15% and 20% by weight aerosol-former.

[0096] The aerosol-forming material may comprise at least 50% by weight aerosol-former, at least 60% by weight aerosol-former, or at least 70% by weight aerosol-former.

[0097] The aerosol-forming material may comprise less than or equal to 85% by weight aerosol-former, less than or equal to 80% by weight aerosol-former, or less than or equal to 75% by weight aerosol-former.

[0098] The aerosol-forming material may comprise between 50% and 85% by weight aerosol-former, between 50% and 80% by weight aerosol-former, or between 50% and 75% by weight aerosol-former.

[0099] The aerosol-forming material may comprise between 60% and 85% by weight aerosol-former, between 60% and 80% by weight aerosol-former, or between 60% and 75% by weight aerosol-former.

[0100] The aerosol-forming material may comprise between 70% and 85% by weight aerosol-former, between 70% and 80% by weight aerosol-former, or between 70% and 75% by weight aerosol-former.

[0101] The aerosol-forming material, for example any one, two or all of the aerosol-forming materials in the aerosol-forming substrate, may comprise nicotine. The aerosol-forming material may comprise natural nicotine, or synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.

[0102] The aerosol-forming material may comprise at least 0.5% by weight nicotine, at least 1% by weight nicotine, at least 1.5% by weight nicotine, or at least 2% by weight nicotine. That is, the aerosol-forming material may have a nicotine content of at least 0.5% by weight, at least 1% by weight, at least 1.5% by weight, or at least 2% by weight.

[0103] The aerosol-forming material, for example any one, two or all of the aerosol-forming materials in the aerosol-forming matrix, may comprise one or more flavoring agents. The one or more flavoring agents may comprise one or more of the following: one or more essential oils, such as eugenol, peppermint oil and spearmint oil; one or both of menthol and eugenol; one or both of anethole and linalool; and herbal materials. Suitable herbal materials include herb leaves or other herbal materials from herbal plants, including but not limited to mint (such as peppermint and spearmint), lemon balm, basil, cinnamon, lemon basil, chives, coriander, lavender, sage, tea, thyme and caraway. The one or more flavoring agents may comprise tobacco materials.

[0104] The aerosol-forming material may have a moisture content of about 5% to 25%, preferably about 7% to 15%, in the final product state. For example, the aerosol-forming substrate may be a homogenised tobacco material having a moisture content of about 5% to 25%, preferably about 7% to 15%, in the final product state.

[0105] The aerosol-forming material may include tobacco leaves; for example, a tobacco leaf blend of about 15% to 45%, preferably about 20% to 35%, comprising at least one of the following tobacco types: flue-cured tobacco; sun-cured tobacco; oriental tobacco. The tobacco material, such as tobacco leaves, is preferably ground and graded to a particle size of about 100 to 380 mesh, preferably about 170 to 320 mesh.

[0106] "Tobacco type" means one of different varieties of tobacco, based, for example, on the different curing processes that the tobacco undergoes before being further processed into tobacco products.

[0107] Examples of flue-cured tobacco are Brazilian flue-cured tobacco, Indian flue-cured tobacco, Chinese flue-cured tobacco, American flue-cured tobacco (such as Virginia tobacco), and flue-cured tobacco from Tanzania.

[0108] Examples of oriental tobaccos are Turkish Oriental, Greek Oriental, Semi-Oriental tobaccos, but also fire-cured American White Burley, such as Perique and Rustica.

[0109] Examples of sun-cured tobacco are dark-cured Brazilian Galpao, Malawi White Burley or other African White Burley, sun-cured or air-cured Indonesian Kasturi.

[0110] The aerosol-forming material may comprise cellulose fibers. For example, the aerosol-forming material may comprise about 1% to 15% cellulose fibers, preferably about 3% to 7% cellulose fibers. Preferably, the cellulose fibers may have a length of about 10 to 250 μm, preferably about 10 to 120 μm.

[0111] The aerosol-forming material may comprise organic fibers, such as non-tobacco fibers or tobacco fibers. For example, the aerosol-forming material may comprise approximately 5% to 20%, preferably approximately 7% to 15% tobacco fibers. The tobacco fibers are preferably derived from stems and / or stalks, which are graded into fibers having a length of approximately 10 to 350 μm, preferably approximately 10 to 180 μm. The aerosol-forming material may comprise approximately 10% to 30%, preferably approximately 15% to 25% non-tobacco organic fibers. For example, the organic fibers may be derived from cellulose, cotton, wood, tea plant varieties that are by-products and by-processing waste of the tea industry. The organic fibers preferably have a length of approximately 10 to 400 μm, preferably approximately 10 to 200 μm.

[0112] The aerosol-forming material may include a binder. For example, the aerosol-forming material may include about 1% to 10%, preferably about 1% to 5%, of a binder, such as any of the common gums or pectins used in the food and beverage (F&B) industry. Preferred binders may be natural pectins (such as fruit, e.g., citrus) or tobacco pectins; guar gum, locust bean gum, such as hydroxyethyl and / or hydroxypropyl derivatives of these; starches, such as modified or derivatized starches; alginates; methyl, ethyl, ethylhydroxymethyl, and carboxymethyl cellulose; dextran; and xanthan gum. A preferred binder is guar gum.

[0113] The aerosol-forming material may comprise an organic vegetable glycerin agent. For example, the aerosol-forming material may comprise about 15% to 55%, preferably about 20% to 35%, of a plant material such as cloves, echinacea, cumin, ginger, hawthorn berries, elderberries, horse mint, mullein leaves, nettles, plantain, turmeric, yarrow, and compounds of these.

[0114] The aerosol-forming material may comprise an organic plant extract. For example, the aerosol-forming material may comprise about 1% to 15%, preferably about 2% to 7%, of any of the previously mentioned plant materials, as well as menthol (dl-menthol, C10H20O, 2-isopropyl-5-methylcyclohexanol) obtained from Chaerophyllum macrospermum, Mesosphaerum sidifolium or other related plant species, and p-menthan-3-ol, which is any secondary alcohol such as a diastereomer of 5-methyl-2-(propan-2-yl)cyclohexane-1-ol.

[0115] The aerosol-forming material may comprise a plant essential oil, for example about 0.5% to 5%, preferably about 1% to 3% of a plant essential oil, for example plant essential oils such as palm oil, coconut oil and wood-based oil.

[0116] The aerosol-forming material preferably comprises an aerosol-forming agent, for example, about 5% to 35%, preferably about 10% to 25% of an aerosol-forming agent. Suitable aerosol-forming agents known in the art include: glycerol; monohydric alcohols such as menthol; polyhydric alcohols such as triethylene glycol; esters of polyhydric alcohols such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl esters of these.

[0117] The aerosol-forming material may comprise particles of a functional material, such as particles of carbon, graphite, activated carbon or expanded graphite. Such materials may, for example, increase the thermal conductivity of the aerosol-forming material and improve the efficiency of aerosol generation.

[0118] The aerosol-forming substrate may further comprise a thermally conductive layer, such as an aluminum layer, covering at least a portion of at least one surface of the aerosol-forming substrate. For example, at least a portion of the upper surface or at least a portion of the lower surface may comprise such a thermally conductive layer. The thermally conductive layer may facilitate heat transfer between the heat source and the aerosol-forming material of the aerosol-forming substrate.

[0119] The aerosol-forming substrate may further comprise a paper layer, such as a tipping paper layer, covering at least a portion of at least one surface of the aerosol-forming substrate, for example at least a portion of the upper surface or at least a portion of the lower surface. The paper layer may protect the user's hands when handling the substrate. The paper layer may be used to allow the user to insert a portion of the aerosol-forming substrate into their mouth.

[0120] The aerosol-forming substrate may comprise a conductive material. For example, the aerosol-forming material may comprise conductive particles. The conductive particles may be, for example, conductive carbon or graphite particles, or conductive metal particles, such as particles of aluminum or stainless steel or nickel.

[0121] The aerosol-forming substrate may include one or more susceptor materials. The one or more susceptor materials may be included within the aerosol-forming material of the aerosol-forming substrate, for example as particles of the susceptor material distributed within the aerosol-forming material. The presence of the susceptor material may allow the aerosol-forming substrate to be heated by engaging with the fluctuating electromagnetic field formed by the inductor.

[0122] Optionally, one or more susceptor materials may be included within the aerosol-forming substrate as one or more strips, threads or filaments of susceptor material, for example one or more strips, threads or filaments of susceptor material located within the airflow path of the aerosol-forming substrate.

[0123] Optionally, one or more susceptor materials may be included within the aerosol-forming substrate as one or more sheets or layers of susceptor material, for example covering an exterior portion of or forming a structural component of the aerosol-forming substrate.

[0124] The aerosol-forming substrate may comprise a first planar layer and a corrugated layer arranged on a surface of the first planar layer, at least one of the first planar layer and the corrugated layer comprising or consisting of a sheet of susceptor material.

[0125] The aerosol-forming substrate may comprise a first planar layer, a second planar layer and a corrugated layer arranged between the first and second planar layers, at least one of the first planar layer, the second planar layer and the corrugated layer comprising or consisting of a sheet of susceptor material.

[0126] The one or more sheets of susceptor material may be in the form of a susceptor material web.

[0127] The susceptor material, in any form, may comprise one or more materials selected from the group consisting of aluminum, iron and iron alloys, nickel and nickel alloys, cobalt alloys, stainless steel alloys, copper alloys, carbon, expanded carbon, and graphite.

[0128] The aerosol-forming substrates disclosed herein may be manufactured using any suitable method. For example, sheets of material comprising an aerosol-forming material may be formed using known methods and assembled together to form the aerosol-forming substrate. In some examples, an extrusion process may be used to form the aerosol-forming substrate.

[0129] Where the substrate comprises a corrugated layer or corrugated elements, it may be advantageous to manufacture the substrate using a process similar to that used to produce corrugated cardboard.

[0130] As disclosed herein, a method for manufacturing a planar corrugated aerosol-forming substrate may include the following steps: providing a first continuous sheet, providing a second continuous sheet, at least one of the first sheet and the second sheet being a sheet comprising or consisting of an aerosol-forming material; texturing the second continuous sheet using a groove roller to form a continuous corrugated sheet; applying an adhesive to at least one of the continuous corrugated sheet or the first continuous sheet; applying the continuous corrugated sheet to a surface of the first continuous sheet to form a continuous aerosol-forming substrate; and cutting the continuous aerosol-forming substrate to form the planar corrugated aerosol-forming substrate.

[0131] A method for manufacturing a planar corrugated aerosol-forming substrate may include the following steps: providing a first continuous sheet, providing a second continuous sheet, and providing a third continuous sheet, at least one of the first sheet, the second continuous sheet, and the second sheet being a sheet comprising or consisting of an aerosol-forming material; texturing the second continuous sheet using a groove roller to form a continuous corrugated sheet; applying an adhesive to at least one of the continuous corrugated sheet or the first continuous sheet; applying a first side of the continuous corrugated sheet to a surface of the first continuous sheet; applying an adhesive to at least one of the continuous corrugated sheet and the third continuous sheet; and applying a second side of the continuous corrugated sheet to a surface of the third continuous sheet, thereby forming a continuous aerosol-forming substrate; and cutting the continuous aerosol-forming substrate to form the planar corrugated aerosol-forming substrate.

[0132] At least one of the first continuous sheet, the second continuous sheet, and the third continuous sheet may be a homogenized tobacco sheet.

[0133] The binder may comprise guar gum.The binder may comprise an aerosol-forming substrate, such as a homogenised tobacco slurry.

[0134] According to the present disclosure, an aerosol-generating article for use with an aerosol-generating article may be provided. The aerosol-generating article may be used to generate an inhalable aerosol. The article comprises an aerosol-forming substrate as disclosed herein. The article may consist entirely of an aerosol-forming substrate as disclosed herein. Advantageously, this may provide one or more of the following benefits: reduced cost of manufacturing the article, reduced article weight and therefore reduced shipping costs of the article, and reduced waste from manufacturing or using the article.

[0135] The aerosol-generating article may comprise an aerosol-forming substrate located within or assembled within an outer wrapper or housing. The outer wrapper or housing may be a cigarette wrapper. The outer wrapper or housing may be a polymer sheet.

[0136] Optionally, the outer packaging or housing may include a portion of a susceptor material, such as aluminum or stainless steel foil.

[0137] Optionally, one or more perforations may be defined through the outer packaging or shell. Such perforations may allow air to flow into or out of the article.

[0138] In some examples, an aerosol-generating article may comprise multiple components, and the multiple components (including the aerosol-forming substrate) may be assembled within an outer packaging or housing.

[0139] Optionally, an aerosol-generating article may comprise two or more aerosol-forming substrates as disclosed herein.

[0140] The aerosol-generating article may be defined by a length extending in the x-direction, a width extending in the y-direction and a height extending in the z-direction.A longitudinal airflow path may be defined through the aerosol-generating article between a distal end of the article and a proximal end of the article.

[0141] The aerosol-generating article may be defined by a length extending in the x-direction between a distal end and a proximal end, a width extending in the y-direction between a first edge and a second edge, and a height extending in the z-direction between an upper surface and a lower surface. A distal portion of the aerosol-generating article may be defined between the distal end of the aerosol-generating article and a longitudinal midpoint of the aerosol-generating article. A proximal portion of the aerosol-generating article may be defined between the proximal end of the aerosol-generating article and a longitudinal midpoint of the aerosol-generating article.

[0142] An aerosol-generating article may comprise a single aerosol-forming substrate extending within the article between a proximal end and a distal end.

[0143] Optionally, the aerosol-forming substrate may be located within a distal portion of the aerosol-generating article. In some examples, the aerosol-forming substrate may be located entirely within the distal portion of the aerosol-generating article. The proximal portion may be a portion of the article configured to be inserted into an aerosol-generating device.

[0144] The aerosol-generating article may further comprise a structural element located proximally relative to the aerosol-forming substrate.The structural element may comprise longitudinal channels or porosity, thereby allowing an airflow path through the structural element.

[0145] The aerosol-forming substrate may be defined by its cross-section, and the structural element may have a similar or identical cross-section as the aerosol-forming substrate, for example a similar rectangular cross-section.The structural element may be a rectangular tube.

[0146] Optionally, the structural element may comprise a corrugated element, for example such that a longitudinal channel within the aerosol-generating article is defined by the corrugated element.The longitudinal channel may be defined by the corrugations of the corrugated element.

[0147] The aerosol-generating article may include a first aerosol-forming substrate as disclosed herein, which is at least partially located within a distal portion of the aerosol-generating article, and a second aerosol-forming substrate as disclosed herein, which is located proximally relative to the first aerosol-forming substrate, for example, at least partially located within a proximal portion of the aerosol-generating article.

[0148] In some examples, an aerosol-generating article comprises a plurality of components, including at least one aerosol-forming substrate as disclosed herein, a substantially hollow structural element such as a hollow tube, and a mouthpiece element such as a mouthpiece filter. The plurality of components may be coaxially aligned and assembled within a wrapper or housing.

[0149] The aerosol-generating article has a length, a width, and a height. Optionally, the length may be greater in magnitude than the width. Optionally, the width may be greater in magnitude than the height.

[0150] The length of the article can be about 1.5 times the magnitude of the width, or about 2 times the magnitude of the width, or about 2.5 times the magnitude of the width, or about 3 times the magnitude of the width. The length can be greater than 3 times the magnitude of the width, such as greater than 4 times the magnitude of the width, such as greater than 5 times the magnitude of the width.

[0151] Preferably, the aerosol-generating article comprises a substantially planar base. For example, the base may be defined by a substantially planar lower surface of the aerosol-forming substrate. In preferred examples, the aerosol-generating article may be in the form of a 3-dimensional shape that can be described as a cuboid or a rectangular prism.

[0152] The length of the article may have a magnitude equal to or greater than 2 times the magnitude of the height, for example 3 times, or 4 times or 5 times the height, optionally equal to or greater than 6 times the height, for example 10 times the height, or 15 times the height or 20 times the height.

[0153] The length of the article may be between 10 mm and 50 mm, for example between 12 mm and 30 mm, for example between 14 mm and 26 mm, for example between 16 mm and 24 mm, for example between 18 mm and 22 mm, for example about 18 mm, or about 19 mm, or about 20 mm, or about 21 mm, or about 22 mm.

[0154] The width of the article may be between 5 mm and 20 mm, such as between 8 mm and 18 mm, such as between 10 mm and 16 mm, such as between 11 mm and 15 mm, such as between 12 mm and 14 mm, such as about 13 mm.

[0155] The height of the article may be between 1 mm and 10 mm, for example between 1.2 mm and 8 mm, for example between 1.4 mm and 7 mm, for example between 1.6 mm and 6 mm, for example between 1.7 mm and 5 mm, for example about 1.7 mm, or about 4.5 mm, or about 2 mm, or about 3 mm, or about 4 mm.

[0156] The aerosol-generating article may comprise a first section and a second section removably coupled to the first section. The first section may comprise an aerosol-forming substrate as described herein, and the second section may be or may comprise a mouthpiece. The second section may be a reusable mouthpiece designed for use with multiple first sections.

[0157] According to the present disclosure, an aerosol-generating device for receiving an aerosol-forming article as disclosed herein or an aerosol-forming substrate as disclosed herein may include a cavity sized to receive at least a portion of the aerosol-generating article or aerosol-forming substrate, a heater or heating device, a power source for supplying power to the heater or heating device, and a controller for controlling the supply of power to the heater or heating device. The aerosol-generating device is configured to heat an aerosol-forming substrate, such as an aerosol-forming substrate that is a component part of an aerosol-generating article, to form an aerosol, such as an inhalable aerosol.

[0158] The cavity may comprise an opening into which the distal end of the aerosol-generating article may be inserted. The cavity may have any suitable cross-sectional shape. For example, the cavity may have a rectangular cross-section, such as a rectangular cross-section having opposing top and bottom sides that are greater in length than left and right sides.

[0159] Preferably, at least one interior surface of the cavity is a heating surface configured to heat the aerosol-generating article. The heating surface may comprise a heater (e.g., a resistive heater or an infrared heater) or a susceptor configured to be heated by engagement with an inductor. The heating surface may comprise an inductor, for example, the surface may comprise a coil arranged to generate a fluctuating electromagnetic field within the cavity. The heating surface may be a surface transparent to the fluctuating electromagnetic field, such that an inductor disposed outside the cavity can project the fluctuating electromagnetic field through the heating surface to engage with a susceptor disposed within the cavity.

[0160] Preferably, at least the lower surface of the cavity is a heated surface configured to heat the aerosol-generating article. Optionally, both the lower and upper surfaces of the cavity are heated surfaces configured to heat the aerosol-generating article.

[0161] Preferably, at least the lower inner surface of the cavity is a substantially planar surface, preferably wherein both the lower inner surface and the upper inner surface of the cavity are substantially planar.Preferably, the upper inner surface and the lower inner surface of the cavity are arranged in parallel relationship to each other.

[0162] Optionally, the upper and lower inner surfaces may converge along the length of the cavity so that they are slightly closer together at the distal end of the cavity than at the proximal end of the cavity. This may allow the cavity to clamp an aerosol-generating article inserted therein. The side inner surfaces may converge in a similar manner to achieve the result of clamping the aerosol-generating article. The upper and lower inner surfaces of the cavity and / or the opposing side surfaces of the cavity may converge between the proximal end and the distal end of the cavity by 1 to 10 degrees, for example, 2 to 8 degrees, for example, 3 to 6 degrees, for example, 4 to 5 degrees.

[0163] In some examples, the lower inner surface and the upper inner surface are movable relative to each other. For example, the lower inner surface and the upper inner surface may be configured to pivot relative to each other, or to move upward and downward relative to each other. This may allow an aerosol-forming substrate or an aerosol-generating article to be easily inserted into the cavity, while allowing the cavity walls to move to hold the substrate or article in position to be heated. For example, relative movement of the upper inner surface and the lower inner surface may cause the aerosol-generating article to be clamped between the two surfaces, facilitating heating of the article and helping to properly position the article within the device.

[0164] The cavity may be defined by a longitudinal dimension or length, a transverse dimension or width, and a depth dimension or height.The length and width are preferably greater in magnitude than the height, for example at least twice the magnitude of the height.

[0165] The device may include a heating surface comprising a plurality of independently operable heating zones, such as two independently operable heating zones, or three independently operable heating zones, or four independently operable heating zones, or five independently operable heating zones, or six independently operable heating zones. A plurality of independently operable heating zones can be configured to be operated individually, or to operate simultaneously in any combination of two or more zones. In some instances, a plurality of independently operable heating zones can be longitudinally spaced apart within the cavity. In some instances, a plurality of independently operable heating zones can be laterally spaced apart within the cavity. Different heating zones can be laterally and longitudinally spaced apart from each other. Different heating zones can be arranged concentrically relative to each other.

[0166] The apparatus may comprise one or more resistive heaters, for example one or more resistive heaters integrated into a wall of the cavity.

[0167] The device may comprise one or more susceptors, for example one or more susceptors integrated into a wall of the cavity or arranged to generate a fluctuating electromagnetic field in or within the wall of the cavity. The one or more walls of the cavity comprise or consist of a susceptor material such that the one or more walls of the cavity heat up when engaged with the fluctuating electromagnetic field, thereby heating the aerosol-generating article inserted into the cavity.

[0168] The device may comprise one or more insertable heating elements arranged to protrude into the cavity for insertion into the aerosol-generating article. The insertable heating element may be arranged to be inserted into a channel defined within the aerosol-generating article, for example, into a channel formed by a corrugated structure of the aerosol-generating article.

[0169] The insertable heating element may be a resistive heater.The insertable heating element may be a susceptor.

[0170] The aerosol-generating device may include a device body. The device body may include a heater. The aerosol-generating device may include a mouthpiece element. The device body may include a device body housing. The device body housing may define a cavity for receiving at least a portion of the aerosol-generating article. The device body and the mouthpiece element may be releasably connected. The mouthpiece element may be releasably connected to the device body (e.g., the device body housing).

[0171] The mouthpiece element may be releasably connectable to the device body (e.g. the device body housing) between a connected position and a disconnected position. In the connected position, the cavity may, for example, be at least partially covered by the mouthpiece element. In the disconnected position, the cavity may be at least partially exposed, for example to allow an article to be inserted into the cavity. The mouthpiece element may, for example, be movable about a hinge relative to the device body between a first position and a second position, for example, be pivotable. In the first position, the cavity may, for example, be at least partially covered by the mouthpiece element. In the second position, the cavity may be at least partially exposed, for example to allow an article to be inserted into the cavity. Advantageously, covering the cavity or the article in the cavity can ensure that most of the aerosol from the article travels along the desired flow path to the user, rather than escaping to the external environment.

[0172] The device (e.g., the device body) may include a power source such as a battery. In use, the power source may provide power to the heater. The device (e.g., the device body) may include a controller. The controller may be configured to control the power from the power source to the heater.

[0173] The device body may include a distal end and a proximal end. The cavity may be defined at the proximal end of the device body. The mouthpiece element may include a distal end and a proximal end. The distal end of the mouthpiece element may be configured to releasably connect to the proximal end of the device body.

[0174] The mouthpiece element or at least a portion of the mouthpiece element may be configured to be inserted into the mouth of a user.The proximal end of the mouthpiece element may be configured to be inserted into the mouth of a user.

[0175] The device (e.g., one or both of the device body and the mouthpiece element) may include an air inlet. The device (e.g., the mouthpiece element) may include an air outlet. The device may include an airflow path fluidly connecting the air inlet to the air outlet. The airflow path may extend through and / or through the cavity. Thus, in use, the device may be configured such that when negative pressure is applied to the air outlet, for example, by a user drawing on the air outlet, air is drawn in through the air inlet, then passes through the aerosol-generating article received in the cavity, thereby entraining aerosol released from the aerosol-forming substrate of the article, and then exits through the air outlet.

[0176] According to the present disclosure, an aerosol-generating system comprises an aerosol-generating device as disclosed herein and an aerosol-generating article as disclosed herein. The system may comprise a plurality of such articles for use with the aerosol-generating device.

[0177] As used herein, the term "aerosol-generating article" may refer to an article that is capable of generating or releasing an aerosol.

[0178] As used herein, the term "aerosol-forming substrate" may refer to a substrate capable of releasing an aerosol or volatile compounds that can form an aerosol. Such volatile compounds may be released by heating the aerosol-forming substrate. The aerosol-forming substrate may comprise an aerosol-forming material. The aerosol-forming substrate may be adsorbed, coated, impregnated or otherwise loaded onto a carrier or support. The aerosol-forming substrate may suitably be part of an aerosol-generating article or smoking article.

[0179] As used herein, the term "aerosol-generating device" may refer to a device for use with an aerosol-generating article to enable the generation or release of an aerosol.

[0180] As used herein, the term "aerosol generating system" refers to the combination of an aerosol generating device and one or more aerosol-forming articles for use with the device. An aerosol generating system may include additional components, such as a charging unit for recharging an onboard power supply in an electrically operated or electric aerosol generating device.

[0181] As used herein, the term "aerosol former" may refer to any suitable known compound or mixture of compounds that promotes the formation of an aerosol in use. The aerosol may be a dense and stable aerosol. The aerosol may be substantially resistant to thermal degradation at the operating temperature of the aerosol-forming substrate or aerosol-generating article.

[0182] As used herein with reference to the present invention, the term "nicotine" is used to describe nicotine, nicotine base, or nicotine salts.

[0183] As used herein with reference to the present invention, the terms “proximal”, “distal”, “upstream” and “downstream” are used to describe the relative positions of components or parts of components of a cartridge and an aerosol generating system.

[0184] 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 and downstream ends of the aerosol-generating article. During use, air may be drawn through the aerosol-generating article in the longitudinal direction.

[0185] As used herein, the term "sheet" refers to a laminar element whose width and length are significantly greater than its thickness. The width of the sheet may be greater than 10 mm, preferably greater than 20 mm or 30 mm. In certain embodiments, a sheet of material used to form an aerosol-forming substrate as described herein may have a thickness of between 10 μm and about 1000 μm, for example, between 10 μm and about 300 μm.

[0186] As used herein, "susceptor" means a conductive element that heats up when subjected to a changing magnetic field. This may be the result of eddy currents and / or hysteresis losses induced in the susceptor element.

[0187] As used herein, term " homogenized tobacco material " contains any tobacco material formed by the agglomeration of the particle of tobacco material.Homogenized tobacco material sheet or web are formed by making particle tobacco agglomerate, and this particle tobacco is by one or both grinding or otherwise powdering and obtains in tobacco leaf blade and the tobacco stem.In addition, homogenized tobacco material can comprise one or more in tobacco dust, tobacco fines and other particle tobacco by-products that form during the processing, operation and transportation of tobacco.Homogenized tobacco material sheet can be produced by casting, extruding, papermaking process or other any suitable technology known in the art.

[0188] The term "cast leaf" is used herein to refer to a product manufactured by a casting process, which is based on a slurry comprising plant particles (e.g., a mixture of clove particles or tobacco particles and clove particles) and a binder (e.g., guar gum) being cast onto a support surface (such as a belt conveyor), drying the slurry and removing the dried sheet from the support surface. The example of casting or cast leaf process is described in US-A-5,724,998, for example, for the manufacture of cast leaf tobacco. In the cast leaf process, granular plant material is produced by pulverizing, grinding or grinding the part of the plant. The particles produced by one or more plants are mixed with a liquid component (typically water) to form a slurry. Other components in the slurry can include fiber, binder and aerosol forming agent. Granular plant material can be agglomerated in the presence of a binder. The slurry is cast onto a support surface and dried into a homogenized plant material sheet. Preferably, the homogenized plant material for the products according to the present invention can be produced by casting. This type of homogenized plant material can include agglomerated granular plant material.

[0189] As used herein, resistance to draw is expressed in pressure units "mmH2O" or "mmWG" or "mm water column" and may be measured according to ISO 6565:2002.

[0190] The present invention is defined in the claims. However, a non-exhaustive list of non-limiting examples is provided below. Any one or more features of these examples may be combined with any one or more features of another example, embodiment or aspect described herein.

[0191] Ex1. An aerosol-forming substrate comprising an aerosol-forming material for generating an aerosol, the aerosol-forming substrate having a base defined by an x dimension extending in the x direction and a y dimension extending in the y direction, and a height defined by a z dimension extending in the z direction.

[0192] Ex2. An aerosol-forming substrate comprising an aerosol-forming material for generating an aerosol, wherein the aerosol-forming substrate is a planar aerosol-forming substrate having a base defined by a length extending in the x-direction, a width extending in the y-direction, and a height extending in the z-direction.

[0193] Ex3. An aerosol-forming substrate comprising an aerosol-forming material for generating an aerosol, the aerosol-forming substrate comprising a substantially planar upper surface defined by a length extending in the x-direction and a width extending in the y-direction, and a substantially planar lower surface defined by a length extending in the x-direction and a width extending in the y-direction, the substantially planar upper surface and the substantially planar lower surface being vertically spaced apart from each other by a height defined in the z-direction.

[0194] Ex3A. An aerosol-forming substrate comprising an aerosol-forming material for generating an aerosol, the aerosol-forming substrate having a base defined by an x dimension and a y dimension, and a height defined by a z dimension, wherein an airflow path is defined through the aerosol-forming substrate from one side of the aerosol-forming substrate to the other side of the aerosol-forming substrate in the x / y plane, wherein the resistance to draw (RTD) of the substrate along the airflow path is less than 20 mm H2O.

[0195] Ex4. An aerosol-forming substrate according to any of the preceding examples, wherein an airflow path is defined as passing through the aerosol-forming substrate from one side of the aerosol-forming substrate to the other side of the aerosol-forming substrate in the x / y plane, wherein the aerosol-forming substrate has a suction resistance in the direction of the airflow path of less than 20 mm H2O, for example, less than 10 mm H2O, for example, less than 8 mm H2O, for example, less than 6 mm H2O, for example, less than 4 mm H2O or preferably less than 2 mm H2O.

[0196] Ex4i. An aerosol-forming substrate according to any preceding example, wherein the aerosol-forming substrate has a resistance to draw of less than 20 mm H2O, such as less than 10 mm H2O, in at least one direction in the x / y plane of the aerosol-forming substrate.

[0197] Ex5. An aerosol-forming substrate according to any preceding example, wherein the aerosol-forming substrate has a resistance to suction in a direction perpendicular to the z-direction, the resistance to suction being less than 20 mm H2O, for example less than 10 mm H2O.

[0198] Ex6. An aerosol-forming substrate according to any of the preceding examples, wherein the airflow path is defined as passing through the aerosol-forming substrate along the x-direction from one side of the aerosol-forming substrate to the other side of the aerosol-forming substrate, so that the aerosol-forming substrate has a suction resistance in the x-direction of less than 20 mm H2O, for example, less than 10 mm H2O.

[0199] Ex7. An aerosol-forming substrate according to any one of Examples Ex1 to Ex5, wherein the airflow path is defined as passing through the aerosol-forming substrate along the y-direction from one side of the aerosol-forming substrate to the other side of the aerosol-forming substrate, so that the aerosol-forming substrate has a suction resistance in the y-direction of less than 20 mm H2O, for example, less than 10 mm H2O.

[0200] Ex8. An aerosol-forming substrate according to any one of Examples Ex4 to Ex7, wherein the resistance to suction is between 9.9 mm H2O and 0 mm H2O, for example between 8 mm H2O and 1 mm H2O, or between 6 mm H2O and 2 mm H2O, or between 5 mm H2O and 3 mm H2O.

[0201] Ex9. An aerosol-forming substrate according to any of the preceding examples, wherein an airflow path is defined as passing through the aerosol-forming substrate in the x / y plane from one side of the aerosol-forming substrate to the other side of the aerosol-forming substrate, wherein the aerosol-forming substrate has a porosity greater than 60%, for example greater than 80%, in the direction of the airflow path.

[0202] Ex9i. An aerosol-forming substrate according to any preceding example, wherein the aerosol-forming substrate has a porosity greater than 60%, such as greater than 80%, in at least one direction in the x / y plane of the aerosol-forming substrate.

[0203] Ex10. The aerosol-forming substrate according to any preceding example, wherein the aerosol-forming substrate has a porosity in a direction perpendicular to the z-direction, the porosity being greater than 60%, such as greater than 80%.

[0204] Ex11. An aerosol-forming substrate according to any of the foregoing examples except Example Ex7, wherein the airflow path is defined as passing through the aerosol-forming substrate along the x-direction from one side of the aerosol-forming substrate to the other side of the aerosol-forming substrate, so that the aerosol-forming substrate has a porosity greater than 60%, for example greater than 80%, in the x-direction.

[0205] Ex12. An aerosol-forming substrate according to any of the foregoing examples except Examples Ex6 and Ex11, wherein the airflow path is defined as passing through the aerosol-forming substrate along the y-direction from one side of the aerosol-forming substrate to the other side of the aerosol-forming substrate, so that the aerosol-forming substrate has a porosity greater than 60%, for example greater than 80%, in the y-direction.

[0206] Ex13. An aerosol-forming substrate according to any one of Examples Ex9 to Ex12, wherein the porosity is between 81% and 99%, such as a porosity between 85% and 95%, such as between 88% and 92%, such as about 90%.

[0207] Ex14. An aerosol-forming substrate according to any preceding example, wherein the substrate comprises an upper layer defining an upper surface and a lower layer defining a lower surface, wherein an airflow path is defined through the aerosol-forming substrate between the upper layer and the lower layer.

[0208] Ex15. An aerosol-forming substrate according to any preceding example, wherein the substrate comprises an upper layer defining an upper surface and a lower layer defining a lower surface, wherein an airflow path is defined between the upper layer and the lower layer through the aerosol-forming substrate from one side to an opposite side.

[0209] Ex16. An aerosol-forming substrate according to any of the preceding examples, wherein the substrate comprises an upper layer defining an upper surface and a lower layer defining a lower surface, wherein an airflow path is defined as passing through the aerosol-forming substrate from one side to an opposite side between the upper layer and the lower layer in an x / y plane.

[0210] Ex17. An aerosol-forming substrate according to example Ex16, wherein a plurality of channels are defined through the aerosol-forming substrate between the upper surface and the lower surface.

[0211] Ex18. An aerosol-forming substrate according to any one of examples Ex16 to Ex17, wherein the aerosol-forming substrate comprises a separation layer located between the upper layer and the lower layer.

[0212] Ex19. An aerosol-forming substrate according to example Ex18, wherein the separation layer comprises one or more ribs or struts separating the upper layer from the lower layer, preferably wherein the ribs or struts extend in a direction defined as an airflow path through the aerosol-forming substrate.

[0213] Ex20. An aerosol-forming substrate according to any preceding example, comprising a corrugated element, such as a sheet of corrugated material.

[0214] Ex21. An aerosol-forming substrate according to example Ex18, wherein the separation layer comprises or consists of a corrugated element, such as a sheet of corrugated material.

[0215] Ex22. An aerosol-forming substrate according to any preceding example, wherein the aerosol-forming substrate comprises an upper layer, a lower layer and a separation layer located between the upper layer and the lower layer, wherein the separation layer comprises one or more corrugated elements.

[0216] Ex23. An aerosol-forming substrate according to example Ex22, wherein the one or more corrugated elements define a plurality of airflow channels extending through the aerosol-forming substrate.

[0217] Ex24. An aerosol-forming substrate according to example Ex22 or Ex23, wherein the aerosol-forming substrate comprises a plurality of corrugated elements, wherein two or more of the plurality of corrugated elements are arranged in a vertical relationship to each other between the upper layer and the lower layer.

[0218] Ex25. An aerosol-forming substrate according to example Ex24, wherein the aerosol-forming substrate comprises an upper corrugated element arranged in contact with the upper layer and a lower corrugated element arranged in contact with the lower layer.

[0219] Ex26. The aerosol-forming substrate according to example Ex25, further comprising at least one additional corrugated element disposed between the upper corrugated element and the lower corrugated element.

[0220] Ex27. An aerosol-forming substrate according to any one of Examples Ex22 to Ex26, wherein the aerosol-forming substrate comprises a plurality of corrugated elements, wherein two or more of the plurality of corrugated elements are arranged in a laterally side-by-side relationship with each other between the upper layer and the lower layer.

[0221] Ex28. An aerosol-forming substrate according to any one of Examples Ex22 to Ex26, wherein the aerosol-forming substrate comprises a plurality of corrugated elements, wherein two or more of the plurality of corrugated elements are arranged in a lateral end-to-end relationship with each other between the upper layer and the lower layer.

[0222] Ex29. An aerosol-forming substrate according to any preceding example, wherein the aerosol-forming substrate has a proximal end and a distal end, defining an airflow path between the proximal end and the distal end.

[0223] Ex30. An aerosol-forming substrate according to example Ex29, wherein the airflow direction extends between the proximal end and the distal end, and wherein the airflow path is defined by at least one corrugated element, the ridges and valleys of the at least one corrugated element being aligned substantially parallel to the airflow direction.

[0224] Ex31. An aerosol-forming substrate according to example Ex30, wherein the aerosol-forming substrate comprises a first corrugated element positioned at or toward the proximal end and a second corrugated element positioned at or toward the distal end, for example, wherein the first corrugated element and the second corrugated element are arranged in a lateral end-to-end relationship with each other between the upper layer and the lower layer, and each corrugated element is aligned substantially parallel to the airflow direction.

[0225] Ex32. An aerosol-forming substrate according to any one of Examples Ex1 to Ex31, comprising an upper layer, a lower layer and an intermediate layer arranged between the upper layer and the lower layer, wherein the upper layer comprises an aerosol-forming material or consists of an aerosol-forming material, and the lower layer and the intermediate layer do not comprise an aerosol-forming material.

[0226] Ex33. An aerosol-forming substrate according to any one of Examples Ex1 to Ex31, comprising an upper layer, a lower layer and an intermediate layer arranged between the upper layer and the lower layer, wherein the lower layer comprises an aerosol-forming material or consists of an aerosol-forming material, and the upper layer and the intermediate layer do not comprise an aerosol-forming material.

[0227] Ex34. An aerosol-forming substrate according to any one of Examples Ex1 to Ex31, comprising an upper layer, a lower layer and an intermediate layer arranged between the upper layer and the lower layer, wherein the intermediate layer comprises an aerosol-forming material or consists of an aerosol-forming material, and the upper layer and the lower layer do not comprise an aerosol-forming material.

[0228] Ex35. An aerosol-forming substrate according to any one of Examples Ex1 to Ex31, comprising an upper layer, a lower layer and an intermediate layer arranged between the upper layer and the lower layer, wherein the lower layer comprises a first aerosol-forming material or consists of a first aerosol-forming material, and the upper layer comprises a second aerosol-forming material or consists of a second aerosol-forming material, and the intermediate layer does not comprise an aerosol-forming material.

[0229] Ex36. An aerosol-forming substrate according to any one of Examples Ex1 to Ex31, comprising an upper layer, a lower layer and an intermediate layer arranged between the upper layer and the lower layer, wherein the lower layer comprises a first aerosol-forming material or consists of a first aerosol-forming material, and the intermediate layer comprises a second aerosol-forming material or consists of a second aerosol-forming material, and the lower layer does not comprise an aerosol-forming material.

[0230] Ex37. An aerosol-forming substrate according to any one of Examples Ex1 to Ex31, comprising an upper layer, a lower layer and an intermediate layer arranged between the upper layer and the lower layer, wherein the upper layer comprises a first aerosol-forming material or consists of a first aerosol-forming material, and the intermediate layer comprises a second aerosol-forming material or consists of a second aerosol-forming material, and the upper layer does not comprise an aerosol-forming material.

[0231] Ex38. An aerosol-forming substrate according to any one of Examples Ex1 to Ex31, comprising an upper layer, a lower layer and an intermediate layer arranged between the upper layer and the lower layer, wherein the upper layer comprises a first aerosol-forming material or consists of a first aerosol-forming material, and the intermediate layer comprises a second aerosol-forming material or consists of a second aerosol-forming material, and the lower layer comprises a third aerosol-forming material or consists of a third aerosol-forming material.

[0232] Ex39. An aerosol-forming substrate according to any one of Examples Ex32 to Ex38, wherein the upper layer comprises or is formed from a sheet of planar material, the lower layer comprises or is formed from a sheet of planar material, and the middle layer comprises or is formed from a sheet of corrugated material.

[0233] Ex40. An aerosol-forming substrate according to any preceding example, comprising a first aerosol-forming material and a second aerosol-forming material.

[0234] Ex41. The aerosol-forming substrate according to example Ex40, further comprising a third aerosol-forming material.

[0235] Ex42. An aerosol-forming substrate according to any one of examples Ex40, wherein the first aerosol-forming material is the same material as the second aerosol-forming material.

[0236] Ex43. An aerosol-forming substrate according to Ex41, wherein the first aerosol-forming material is the same material as the third aerosol-forming material, for example, wherein the first aerosol-forming material, the second aerosol-forming material and the third aerosol-forming material are all the same aerosol-forming material.

[0237] Ex44. An aerosol-forming substrate according to example Ex40, wherein the first aerosol-forming material is different from the second aerosol-forming material, for example has a different composition than the second aerosol-forming material, for example has a different aerosol former content or a different flavor content.

[0238] Ex45. An aerosol-forming matrix according to example Ex41, wherein the first aerosol-forming material is different from the third aerosol-forming material, for example having a different composition than the second aerosol-forming material, for example having a different aerosol-forming agent content or a different flavor content, for example wherein the first aerosol-forming material, the second aerosol-forming material and the third aerosol-forming material are all different materials.

[0239] Ex46. An aerosol-forming substrate according to any preceding example, wherein the aerosol-forming material is a homogenized tobacco material, for example, wherein any of the first aerosol-forming material, the second aerosol-forming material or the third aerosol-forming material is a homogenized tobacco material.

[0240] Ex47. An aerosol-forming substrate according to any preceding example, comprising an upper layer, a lower layer and an intermediate layer arranged between the upper layer and the lower layer, wherein the intermediate layer is fixed relative to at least one of the upper layer and the lower layer by an adhesive.

[0241] Ex48. An aerosol-forming substrate according to example Ex47, wherein the binder is an aerosol-forming material, for example wherein the binder is a homogenised tobacco slurry, or wherein the binder is a flavouring and / or an aerosol-forming agent or comprises a flavouring and / or an aerosol-forming agent.

[0242] Ex49. The aerosol-forming substrate according to example Ex47 or Ex48, wherein the intermediate layer comprises or consists of a corrugated element.

[0243] Ex50. An aerosol-forming substrate according to any preceding example, wherein an airflow path is defined through the substrate by channels formed by the longitudinally extending corrugations of the corrugated element.

[0244] Ex51. An aerosol-forming substrate according to example Ex50, wherein a porous material is located within the channels formed by the longitudinally extending corrugations.

[0245] Ex52. An aerosol-forming substrate according to example Ex51, wherein the porous material comprises or consists of an aerosol-forming material.

[0246] Ex53. An aerosol-forming substrate according to example Ex51 or Ex52, wherein the porous material comprises a flavoring.

[0247] Ex54. An aerosol-forming substrate according to any one of examples Ex50 to Ex53, wherein flavoring agents, such as flavor threads and / or one or more flavor capsules, are located within the channels formed by the longitudinally extending corrugations to release flavor upon heating.

[0248] Ex55. An aerosol-forming substrate according to any preceding example, wherein an airflow path or the airflow path is defined as passing through the aerosol-forming substrate from one side of the aerosol-forming substrate to the other side of the aerosol-forming substrate in the x / y plane.

[0249] Ex56. An aerosol-forming substrate according to example Ex55, wherein the airflow path passes through a filter or a mesh or a porous material, such as a porous paper, e.g. a tea bag material, comprised in the aerosol-forming substrate.

[0250] Ex57. An aerosol-forming substrate according to example Ex56, wherein the filter or mesh or porous material, such as porous paper, for example tea bag material, is arranged transverse to the airflow path, for example across the proximal or downstream end of the aerosol-forming substrate.

[0251] Ex58. An aerosol-forming substrate according to any of the preceding examples, comprising a substantially planar layer and a corrugated layer fixed to the surface of the substantially planar layer, such that the longitudinal channels formed by the longitudinally extending corrugations of the corrugated layer extend in the planar direction of the substantially planar layer.

[0252] Ex59. An aerosol-forming substrate according to any of the preceding examples, comprising an upper layer, a lower layer and an intermediate layer, wherein at least one of the upper layer and the lower layer comprises perforations or holes so that at least a portion of the air can flow through the upper layer and / or the lower layer.

[0253] Ex60. An aerosol-forming substrate according to example Ex59, wherein the aerosol-forming substrate comprises a proximal or oral end and a distal end, and wherein the perforations or holes are located in a central portion of the aerosol-forming substrate, for example approximately midway between the proximal or oral end and the distal end.

[0254] Ex61. An aerosol-forming substrate according to example Ex59 or Ex60, wherein the intermediate layer comprises or consists of a corrugated element or layer arranged between the upper layer and the lower layer, so that the longitudinal channels formed by the longitudinally extending corrugations of the corrugated element or layer extend in the planar direction of the upper layer and the lower layer.

[0255] Ex62. An aerosol-forming substrate according to example Ex61, wherein the intermediate layer comprises perforations or holes such that at least a portion of the air can flow through the intermediate layer in a direction perpendicular to the longitudinally extending channels.

[0256] Ex63. An aerosol-forming substrate according to any of the foregoing examples, comprising an upper layer, a lower layer and an intermediate layer, wherein the intermediate layer comprises a corrugated element or layer arranged between the upper layer and the lower layer or consists of the corrugated element or layer, so that the longitudinal channel formed by the longitudinally extending corrugations of the corrugated element or layer extends in the planar direction of the upper layer and the lower layer, and wherein the intermediate layer comprises perforations or holes so that at least a portion of the air can flow through the intermediate layer in a direction perpendicular to the longitudinally extending channel.

[0257] Ex64. An aerosol-forming substrate according to example Ex63, wherein the intermediate layer is a mesh.

[0258] Ex65. An aerosol-forming substrate according to example Ex63 or Ex64, wherein the aerosol-forming substrate includes a proximal end or an oral end and a distal end, and wherein the longitudinal channel formed by the longitudinally extending corrugations of the corrugated element or layer extends in a direction perpendicular to the direction defined between the proximal end or an oral end and the distal end.

[0259] Ex65A. An aerosol-generating substrate according to any preceding example, comprising one or more sheets of aerosol-forming material, wherein a plurality of holes or recesses are defined in a surface, such as an upper surface or a lower surface, of the aerosol-forming material.

[0260] Ex65B. An aerosol-generating substrate according to any of the foregoing examples, wherein the aerosol-forming substrate comprises a lower layer of aerosol-forming material and a corrugated layer attached to the lower layer, such as a corrugated layer of aerosol-forming material, wherein a plurality of holes or recesses are defined in at least one of the lower layer of aerosol-forming material and the corrugated layer.

[0261] Ex65C. An aerosol-forming substrate according to any preceding example, wherein a plurality of holes or recesses are defined in the upper surface of the aerosol-forming substrate.

[0262] Ex65D. An aerosol-generating article according to examples Ex65A to Ex65C, wherein at least a portion of the plurality of holes are blind holes that do not extend through the thickness of the aerosol-forming material in which the blind holes are defined.

[0263] Ex65E. An aerosol-generating article according to any one of examples Ex65A to Ex65D, wherein at least a portion of the plurality of holes are through-holes extending through the thickness of the aerosol-forming material in which the through-holes are defined.

[0264] Ex66. An aerosol-forming substrate comprising a first planar layer and a corrugated layer arranged on a surface of the first planar layer, at least one of the first planar layer and the corrugated layer comprising or consisting of an aerosol-forming material.

[0265] Ex67. An aerosol-forming substrate comprising a first planar layer, a second planar layer, and a corrugated layer arranged between the first planar layer and the second planar layer, wherein at least one of the first planar layer, the second planar layer, and the corrugated layer comprises an aerosol-forming material or is composed of an aerosol-forming material.

[0266] Ex68. An aerosol-forming substrate comprising a first layer and a corrugated layer attached to a surface of the first layer by an adhesive, wherein the adhesive comprises or consists of an aerosol-forming material.

[0267] Ex69. An aerosol-forming substrate comprising a first layer, a second layer and an intermediate layer arranged between the first layer and the second layer, wherein the intermediate layer is attached to the first layer and / or the second layer by an adhesive, wherein the adhesive comprises an aerosol-forming material or consists of an aerosol-forming material.

[0268] Ex70. An aerosol-forming substrate comprising a first layer and a corrugated layer attached to a surface of the first layer, a plurality of longitudinally extending channels defined by the corrugations between the first layer and the second layer, wherein a porous element is located in at least one of the longitudinally extending channels.

[0269] Ex71. An aerosol-forming substrate comprising a first layer and a corrugated layer attached to a surface of the first layer, a plurality of longitudinally extending channels defined by corrugations between the first layer and the corrugated layer, wherein the longitudinally extending channels are filled with a porous material, such as a porous aerosol-forming material.

[0270] Ex72. An aerosol-forming substrate comprising a first layer, a second layer and a corrugated layer arranged between the first layer and the second layer, a plurality of longitudinally extending channels being defined by corrugations between the first layer and the corrugated layer and between the corrugated layer and the second layer, wherein a porous element is located in at least one of the longitudinally extending channels.

[0271] Ex73. An aerosol-forming substrate comprising a first layer and a corrugated layer attached to a surface of the first layer, a plurality of longitudinally extending channels defined by corrugations between the first layer and the corrugated layer, wherein one or more flavor release components, such as components such as wires or capsules impregnated with flavor components or containing flavor components, are located within at least one of the longitudinally extending channels.

[0272] Ex74. An aerosol-forming substrate comprising a first layer, a second layer and a corrugated layer arranged between the first layer and the second layer, a plurality of longitudinally extending channels being defined by corrugations between the first layer and the corrugated layer and between the corrugated layer and the second layer, wherein one or more flavor release components, such as components such as wires or capsules impregnated with flavor components or containing flavor components, are located within at least one of the longitudinally extending channels.

[0273] Ex75. An aerosol-forming substrate comprising a first planar layer and a corrugated layer arranged on a surface of the first planar layer, at least one of the first planar layer and the corrugated layer comprising perforations or holes to allow air to flow through the first planar layer or the corrugated layer.

[0274] Ex76. An aerosol-forming substrate comprising a first planar layer, a second planar layer, and a corrugated layer arranged between the first planar layer and the second planar layer, wherein at least one of the first planar layer, the second planar layer, and the corrugated layer comprises perforations or holes to allow air to flow through the first planar layer, the second planar layer, or the corrugated layer.

[0275] Ex77. An aerosol-forming substrate comprising a first planar layer, a second planar layer, and a third planar layer arranged between the first planar layer and the second planar layer, the aerosol-forming substrate further comprising a first corrugated layer arranged between the first planar layer and the third planar layer, and a second corrugated layer arranged between the third planar layer and the second planar layer.

[0276] Ex78. An aerosol-forming substrate according to any preceding example, comprising a corrugated element or layer, wherein the corrugations of the corrugated element or layer are defined by a corrugation wavelength and a corrugation amplitude.

[0277] Ex79. An aerosol-forming substrate according to example Ex78, wherein the corrugation wavelength is between 1 mm and 10 mm, for example between 1.5 mm and 8 mm, for example between 2 mm and 6 mm, for example between 2.5 mm and 5 mm, for example between 3 mm and 4 mm.

[0278] Ex80. An aerosol-forming substrate according to example Ex78 or Ex79, wherein the corrugation amplitude or z-axis thickness of the corrugated element or layer is between 1 mm and 10 mm, for example between 1.5 mm and 8 mm, for example between 2 mm and 6 mm, for example between 2.5 mm and 5 mm, for example between 3 mm and 4 mm.

[0279] Ex80A. An aerosol-forming substrate according to any of the examples, comprising at least one planar layer and at least one corrugated layer, wherein the thickness of the at least one planar layer is between 0.02 mm and 2 mm, for example between 0.05 mm and 1.5 mm, for example between 0.1 mm and 1 mm, for example between 0.2 mm and 0.8 mm, for example between 0.3 mm and 0.6 mm, for example between 0.4 mm and 0.5 mm.

[0280] Ex81. An aerosol-forming substrate according to any one of Examples Ex78 to Ex80, wherein the corrugations can also be defined by a corrugation profile, wherein the corrugation profile is sinusoidal, or triangular, or rectangular, or trapezoidal, or annular, or parabolic.

[0281] Ex82. An aerosol-forming substrate according to any of the preceding examples, wherein the aerosol-forming substrate is formed as an extrudate of an aerosol-forming material, the extrudate having an upper surface, a lower surface and a plurality of airflow channels defined through the aerosol-forming substrate between the upper surface and the lower surface.

[0282] Ex83. An aerosol-forming substrate according to any preceding example, wherein the length (x dimension) is approximately the same magnitude as the width (y dimension).

[0283] Ex84. An aerosol-forming substrate according to any one of Examples Ex1 to Ex82, wherein the length (x dimension) is greater in magnitude than the width (y dimension), for example, wherein the length is about 1.5 times the magnitude of the width, or about 2 times the magnitude of the width, or about 2.5 times the magnitude of the width, or about 3 times the magnitude of the width.

[0284] Ex85. An aerosol-forming substrate according to example Ex84, wherein the length (x dimension) is greater than 3 times the magnitude of the width, for example greater than 4 times the magnitude of the width, for example greater than 5 times the magnitude of the width.

[0285] Ex86. An aerosol-forming substrate according to any preceding example, having a base, wherein the base is substantially planar, for example wherein the base defines a substantially planar lower surface of the aerosol-forming substrate.

[0286] Ex87. An aerosol-forming substrate according to any preceding example, wherein the aerosol-forming substrate is in the form of a 3-dimensional shape that can be described as a cuboid or a rectangular prism.

[0287] Ex88. An aerosol-forming substrate according to any of the preceding examples, wherein one or both of the length (x dimension) and the width (y dimension) have a magnitude equal to or greater than 2 times the magnitude of the height (z dimension), for example 3 times, or 4 times or 5 times the height, optionally equal to or greater than 6 times the height, for example 10 times the height, or 15 times the height or 20 times the height.

[0288] Ex89. An aerosol-forming substrate according to any of the foregoing examples, having a base, wherein the base is defined by a rectangular shape having a length and width forming a lower surface of the aerosol-forming substrate, and the upper surface of the aerosol-forming substrate is defined by a substantially identical rectangular shape spaced apart from the base by the height, for example wherein both the lower surface and the upper surface are defined as planar surfaces lying on parallel planes spaced apart by the height.

[0289] Ex90. An aerosol-forming substrate according to any of the preceding examples, wherein the ratio of the largest of its length (x dimension) and its width (y dimension) in magnitude to its height (z dimension) is between 4:1 and 20:1, for example between 4.2:1 and 10:1, for example between 4.5:1 and 8:1, for example wherein the ratio of length to width is between 4:1 and 20:1, for example between 4.2:1 and 10:1, for example between 4.5:1 and 8:1.

[0290] Ex91. An aerosol-forming substrate according to any of the preceding examples, wherein the length (x dimension) of the substrate is between 10 mm and 50 mm, for example between 12 mm and 30 mm, for example between 14 mm and 26 mm, for example between 16 mm and 24 mm, for example between 18 mm and 22 mm, for example about 18 mm, or about 19 mm, or about 20 mm, or about 21 mm, or about 22 mm.

[0291] Ex92. An aerosol-forming substrate according to any of the preceding examples, wherein the width (y dimension) of the substrate is between 5 mm and 20 mm, for example between 8 mm and 18 mm, for example between 10 mm and 16 mm, for example between 11 mm and 15 mm, for example between 12 mm and 14 mm, for example about 13 mm.

[0292] Ex93. An aerosol-forming substrate according to any of the preceding examples, wherein the height (z dimension) of the substrate is between 1 mm and 10 mm, for example, between 1.2 mm and 8 mm, for example, between 1.4 mm and 7 mm, for example, between 1.6 mm and 6 mm, for example, between 1.7 mm and 5 mm, for example, about 1.7 mm, or about 4.5 mm, or about 2 mm, or about 3 mm, or about 4 mm.

[0293] Ex94. An aerosol-forming substrate according to any preceding example, wherein the aerosol-forming substrate consists entirely of an aerosol-forming material.

[0294] Ex95. An aerosol-forming substrate according to any preceding example, further comprising a porous layer covering at least one surface of the aerosol-forming substrate, such as at least the upper surface, or at least the lower surface, or at least the upper and lower surfaces.

[0295] Ex96. An aerosol-forming substrate according to any preceding example, further comprising a porous layer covering at least an end surface of the aerosol-forming substrate, for example covering at least at least one airflow inlet or outlet of the aerosol-forming substrate.

[0296] Ex97. An aerosol-forming substrate according to example Ex95 or Ex96, wherein the porous layer completely encapsulates the aerosol-forming substrate.

[0297] Ex98. The aerosol-forming substrate according to example Ex95, Ex96 or Ex97, wherein the porous layer is a porous paper or a porous mesh.

[0298] Ex99. An aerosol-forming substrate according to any preceding example, wherein the aerosol-forming substrate comprises nicotine.

[0299] Ex100. An aerosol-forming substrate according to any preceding example, wherein the aerosol-forming substrate comprises or consists of a homogenised tobacco material.

[0300] Ex101. An aerosol-forming substrate according to any preceding example, wherein the aerosol-forming substrate comprises or consists of a solid aerosol-forming material.

[0301] Ex102. An aerosol-forming substrate according to any preceding example, wherein the aerosol-forming substrate comprises a liquid aerosol-forming material held within a porous matrix.

[0302] Ex103. An aerosol-forming substrate according to any preceding example, wherein the aerosol-forming substrate comprises a gel aerosol-forming material.

[0303] Ex104. An aerosol-forming substrate according to any preceding example, wherein a first portion of the aerosol-forming substrate comprises a first aerosol-forming material, and a second portion of the aerosol-forming substrate comprises a second aerosol-forming material different from the first aerosol-forming material.

[0304] Ex105. The aerosol-forming substrate according to example Ex104, wherein the first aerosol-forming material is a first homogenised tobacco material, and the second aerosol-forming material is a second homogenised tobacco material having a different composition than the first homogenised tobacco material.

[0305] Ex106. An aerosol-forming substrate according to example Ex105, wherein the first homogenized tobacco material differs from the second tobacco composition by having at least one difference selected from the group consisting of: different aerosol-forming agent content, different tobacco content, different flavoring agent content, different water content, and different nicotine content.

[0306] Ex107. An aerosol-forming substrate according to example Ex104, wherein the first aerosol-forming material is a first homogenized tobacco material and the second aerosol-forming material is a non-tobacco aerosol-forming material, the non-tobacco aerosol-forming material comprising an aerosol-forming agent such as glycerol or propylene glycol, preferably comprising a flavor component and / or an active component, such as nicotine.

[0307] Ex108. An aerosol-forming substrate according to any of the preceding examples, further comprising a thermally conductive layer, such as an aluminum layer, covering at least a portion of at least one surface of the aerosol-forming substrate, such as at least a portion of the upper surface or at least a portion of the lower surface.

[0308] Ex109. An aerosol-forming substrate according to any preceding example, further comprising a paper layer, such as a tipping paper layer, covering at least a portion of at least one surface of the aerosol-forming substrate, such as at least a portion of the upper surface or at least a portion of the lower surface.

[0309] Ex110. An aerosol-forming substrate according to any of the foregoing examples, comprising at least one aerosol-forming material, wherein the aerosol-forming material comprises one or more organic materials such as tobacco, for example, wherein the aerosol-forming material comprises one or more of herb leaves, tobacco leaves, fragments of tobacco ribs, reconstituted tobacco, homogenized tobacco, extruded tobacco and expanded tobacco.

[0310] Ex111. An aerosol-forming substrate according to any of the foregoing examples, comprising at least one aerosol-forming material, said aerosol-forming material comprising one or more aerosol-forming agents, for example one or more aerosol-forming agents selected from the following: polyols, such as propylene glycol, polyethylene glycol, triethylene glycol, 1,3-butylene glycol and glycerol; esters of polyols, such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate, preferably wherein the aerosol-forming agent is glycerol or comprises glycerol.

[0311] Ex112. An aerosol-forming substrate according to example Ex111, wherein the aerosol-forming material comprises at least 1 wt% aerosol-forming agent, for example at least 2 wt%, 5 wt%, 10 wt% or 15 wt% aerosol-forming agent.

[0312] Ex112A. An aerosol-forming substrate according to example Ex112, wherein the aerosol-forming material comprises greater than 15 wt% aerosol-forming agent, for example greater than 20 wt%, or greater than 25 wt%, or greater than 30 wt%, or greater than 40 wt% or greater than 50 wt% aerosol-forming agent.

[0313] Ex113. An aerosol-forming substrate according to any preceding example, comprising at least one aerosol-forming material, said aerosol-forming material comprising nicotine.

[0314] Ex113A. An aerosol-forming substrate according to example Ex113, wherein the aerosol-forming material comprises at least 0.5 wt% nicotine, such as at least 1 wt% nicotine, or at least 1.5 wt% nicotine or at least 2 wt% nicotine.

[0315] Ex115. An aerosol-forming substrate according to any of the preceding examples, comprising at least one aerosol-forming material, the aerosol-forming material comprising one or more flavoring agents, for example, wherein the one or more flavoring agents comprise: one or more essential oils, such as eugenol, peppermint oil, and spearmint oil; one or both of menthol and eugenol; one or both of anethole and linalool; and herbal materials, such as herb leaves or other herbal materials from herbal plants, the herbal plants including, for example, mint (such as peppermint and spearmint), lemongrass, basil, cinnamon, lemon basil, chives, coriander, lavender, sage, tea, thyme, and caraway.

[0316] Ex116. An aerosol-forming substrate according to any preceding example, comprising at least one aerosol-forming material comprising particles of a functional material, such as particles of carbon, graphite, activated carbon or expanded graphite.

[0317] Ex117. An aerosol-forming substrate according to any preceding example, comprising at least one aerosol-forming material comprising non-tobacco fibers, such as non-tobacco cellulosic fibers.

[0318] Ex118. An aerosol-forming substrate according to any preceding example, comprising at least one aerosol-forming material comprising a binder, such as guar gum.

[0319] Ex119. An aerosol-forming substrate according to any preceding example, comprising at least one aerosol-forming material comprising conductive particles, such as conductive carbon or graphite particles or conductive metal particles, such as particles of aluminum or stainless steel or nickel.

[0320] Ex120. An aerosol-forming substrate according to any preceding example, comprising one or more susceptor materials.

[0321] Ex121. An aerosol-forming substrate according to example Ex120, wherein one or more susceptor materials are included within the aerosol-forming material of the aerosol-forming substrate, for example as particles of the susceptor material distributed within the aerosol-forming material.

[0322] Ex122. An aerosol-forming substrate according to example Ex120 or Ex121, wherein one or more receptor materials are included within the aerosol-forming substrate as one or more receptor material strips, threads or filaments, for example one or more receptor material strips, threads or filaments located within the airflow path of the aerosol-forming substrate.

[0323] Ex123. An aerosol-forming substrate according to any one of Examples Ex120 to Ex122, wherein one or more receptor materials are included within the aerosol-forming substrate as one or more receptor material sheets or layers, for example, one or more receptor material sheets or layers covering an external portion of the aerosol-forming substrate or forming a structural component of the aerosol-forming substrate.

[0324] Ex124. An aerosol-forming substrate according to any one of Examples Ex120 to Ex123, wherein the aerosol-forming substrate comprises a first planar layer and a corrugated layer arranged on the surface of the first planar layer, at least one of the first planar layer and the corrugated layer comprising or consisting of a sheet of a susceptor material.

[0325] Ex125. An aerosol-forming substrate according to any one of Examples Ex120 to Ex124, comprising a first planar layer, a second planar layer and a corrugated layer arranged between the first planar layer and the second planar layer, wherein at least one of the first planar layer, the second planar layer and the corrugated layer comprises a sheet of a susceptor material or consists of a sheet of a susceptor material.

[0326] Ex126. The aerosol-forming substrate according to any one of examples Ex123 to Ex125, wherein the one or more sheets of susceptor material are in the form of a susceptor material web.

[0327] Ex127. The aerosol-forming substrate according to any one of Examples Ex120 to Ex126, wherein the susceptor material comprises one or more materials selected from the group consisting of aluminum, iron and iron alloys, nickel and nickel alloys, cobalt alloys, stainless steel alloys, copper alloys, carbon, expanded carbon, and graphite.

[0328] Ex128. An aerosol-generating article for use with an aerosol-generating device to generate an inhalable aerosol, the aerosol-generating article consisting of an aerosol-forming substrate according to any one of Examples Ex1 to Ex127.

[0329] Ex129. An aerosol-generating article for use with an aerosol-generating device to generate an inhalable aerosol, the aerosol-generating article comprising an aerosol-forming substrate according to any one of Examples Ex1 to Ex127.

[0330] Ex130. An aerosol-generating article according to example Ex129, wherein the aerosol-forming substrate is located within an outer packaging or housing.

[0331] Ex131. An aerosol-generating article according to example Ex130, wherein the outer packaging or casing is a cigarette packaging.

[0332] Ex132. An aerosol-generating article according to example Ex130, wherein the outer packaging or housing is a polymer sheet.

[0333] Ex133. An aerosol-generating article according to any one of Examples Ex130 to Ex132, wherein the outer packaging or housing comprises a portion of a susceptor material, such as aluminum or stainless steel foil.

[0334] Ex134. An aerosol-generating article according to any one of Examples Ex130 to Ex133, wherein one or more perforations are defined through the outer packaging or housing.

[0335] Ex135. An aerosol-generating article according to any one of Examples Ex130 to Ex133, wherein a plurality of components including the aerosol-forming substrate are assembled within the outer packaging or housing.

[0336] Ex136. An aerosol-generating article according to any one of Examples Ex129 to Ex133, comprising two or more aerosol-forming substrates according to any one of Examples Ex1 to Ex128.

[0337] Ex137. An aerosol-generating article according to any one of Examples Ex128 to Ex136, wherein the aerosol-generating article has a length extending in the x-direction, a width extending in the y-direction, and a height extending in the z-direction, and a longitudinal airflow path is defined as passing through the aerosol-generating article between the distal end of the article and the proximal end of the article.

[0338] Ex138. An aerosol-generating article according to any one of Examples Ex128 to Ex137, wherein the aerosol-generating article has a length extending in the x-direction between the distal end and the proximal end, a width extending in the y-direction between the first edge and the second edge, and a height extending in the z-direction between the upper surface and the lower surface, preferably, the distal portion of the aerosol-generating article is defined between the distal end of the aerosol-generating article and the longitudinal midpoint of the aerosol-generating article, and the proximal portion of the aerosol-generating article is defined between the proximal end of the aerosol-generating article and the longitudinal midpoint of the aerosol-generating article.

[0339] Ex139. An aerosol-generating article according to example Ex137 or Ex138, comprising a single aerosol-forming substrate according to any one of examples Ex1 to Ex128, the single aerosol-forming substrate extending within the article between the proximal end and the distal end.

[0340] Ex140. An aerosol-generating article according to example Ex138 or Ex139, comprising an aerosol-forming substrate according to any one of examples Ex1 to Ex128, the aerosol-forming substrate being located within a distal portion of the aerosol-generating article.

[0341] Ex141. An aerosol-generating article according to example Ex138 or Ex139, comprising an aerosol-forming substrate according to any one of examples Ex1 to Ex128, the aerosol-forming substrate being entirely located within the distal portion of the aerosol-generating article.

[0342] Ex142. An aerosol-generating article according to example Ex140 or Ex141, further comprising a structural element located proximally relative to the aerosol-forming substrate, the structural element having longitudinal channels or porosity allowing an airflow path through the structural element.

[0343] Ex143. An aerosol-generating article according to example Ex142, wherein the aerosol-forming substrate has a cross-section, and the structural elements have similar or identical cross-sections, such as similar rectangular cross-sections.

[0344] Ex144. An aerosol-generating article according to example Ex142 or Ex143, wherein the structural element is a rectangular tube.

[0345] Ex145. An aerosol-generating article according to example Ex142 or Ex143, wherein the structural element comprises a corrugated element, and the longitudinal channels in the aerosol-generating article are defined by the corrugated element.

[0346] Ex146. An aerosol-generating article according to example Ex145, wherein the structural element comprises a corrugated element, the longitudinal channels within the aerosol-generating article being defined by the corrugations of the corrugated element.

[0347] Ex147. An aerosol-generating article according to example Ex138 or Ex139, comprising a first aerosol-forming substrate according to any one of examples Ex1 to Ex128, which is at least partially located within a distal portion of the aerosol-generating article, and a second aerosol-forming substrate according to any one of examples Ex1 to Ex128, which is located proximally relative to the first aerosol-forming substrate, for example, at least partially located within a proximal portion of the aerosol-generating article.

[0348] Ex148. An aerosol-generating article according to any one of Examples Ex130 to Ex147, comprising a plurality of components coaxially aligned and assembled within a package or shell, the plurality of components comprising at least one aerosol-forming substrate according to any one of Examples Ex1 to Ex128, a substantially hollow structural element such as a hollow tube, and a mouthpiece element such as a mouthpiece filter.

[0349] Ex149. An aerosol-generating article according to any one of Examples Ex128 to Ex148, the aerosol-generating article having a length, a width and a height, wherein the length is greater in magnitude than the width, and wherein the width is greater in magnitude than the height.

[0350] Ex150. An aerosol-generating article according to example Ex149, wherein the length is about 1.5 times the magnitude of the width, or about 2 times the magnitude of the width, or about 2.5 times the magnitude of the width, or about 3 times the magnitude of the width.

[0351] Ex151. An aerosol-generating article according to example Ex149 or Ex150, wherein the length is greater than 3 times the magnitude of the width, for example greater than 4 times the magnitude of the width, for example greater than 5 times the magnitude of the width.

[0352] Ex152. An aerosol-generating article according to any one of examples Ex149 to Ex151, wherein the article comprises a substantially planar base, for example wherein the base defines a substantially planar lower surface of the aerosol-forming substrate.

[0353] Ex153. An aerosol-generating article according to any one of examples Ex149 to Ex152, wherein the aerosol-generating article is in the form of a 3-dimensional shape that can be described as a cuboid or a rectangular prism.

[0354] Ex154. An aerosol-generating article according to any one of Examples Ex149 to Ex153, wherein the length has a value equal to or greater than 2 times the value of the height, for example 3 times, or 4 times or 5 times the height, optionally equal to or greater than 6 times the height, for example 10 times the height, or 15 times the height or 20 times the height.

[0355] Ex155. An aerosol-generating article according to any one of Examples Ex128 to Ex154, wherein the length of the article is between 10 mm and 50 mm, for example, between 12 mm and 30 mm, for example, between 14 mm and 26 mm, for example, between 16 mm and 24 mm, for example, between 18 mm and 22 mm, for example, about 18 mm, or about 19 mm, or about 20 mm, or about 21 mm, or about 22 mm.

[0356] Ex156. An aerosol-generating article according to any one of Examples Ex128 to Ex155, wherein the width of the article is between 5 mm and 20 mm, for example between 8 mm and 18 mm, for example between 10 mm and 16 mm, for example between 11 mm and 15 mm, for example between 12 mm and 14 mm, for example about 13 mm.

[0357] Ex157. An aerosol-generating article according to any one of Examples Ex128 to Ex156, wherein the height of the article is between 1 mm and 10 mm, for example, between 1.2 mm and 8 mm, for example, between 1.4 mm and 7 mm, for example, between 1.6 mm and 6 mm, for example, between 1.7 mm and 5 mm, for example, about 1.7 mm, or about 4.5 mm, or about 2 mm, or about 3 mm, or about 4 mm.

[0358] Ex157A. An aerosol-generating article according to any one of Examples Ex128 to Ex157, wherein the article comprises a first section and a second section removably connected to the first section, wherein the first section comprises an aerosol-forming substrate according to any one of Examples Ex1 to Ex127, and wherein the second section is a mouthpiece.

[0359] Ex157B. An aerosol-generating article according to example Ex157A, wherein the second section is a reusable mouthpiece designed for use with a plurality of first sections.

[0360] Ex158. An aerosol generating device for receiving an aerosol-forming article according to any one of Examples Ex129 to Ex157 to form an inhalable aerosol, the aerosol generating device comprising a cavity sized to receive at least a portion of the aerosol generating article, a heater or heating device, a power source for supplying power to the heater or heating device, and a controller for controlling the supply of power to the heater or heating device.

[0361] Ex159. An aerosol-generating device according to example Ex158, wherein the cavity comprises an opening into which the distal end of the aerosol-generating article is insertable.

[0362] Ex160. An aerosol generating device according to any one of Examples Ex158 to Ex159, wherein the cavity has a rectangular cross-section, for example a rectangular cross-section having a top side and a bottom side that are longer than left and right sides.

[0363] Ex161. An aerosol-generating device according to any one of Examples Ex158 to Ex160, wherein at least one inner surface of the cavity is a heating surface configured to heat the aerosol-generating article, such as a surface comprising a heater or a surface comprising an inductor.

[0364] Ex162. An aerosol-generating device according to example Ex161, wherein at least the lower surface of the cavity is a heating surface configured to heat the aerosol-generating article.

[0365] Ex163. An aerosol-generating device according to example Ex162, wherein both the lower surface and the upper surface of the cavity are heating surfaces configured to heat the aerosol-generating article.

[0366] Ex164. An aerosol generating device according to any one of Examples Ex158 to Ex163, wherein at least the lower inner surface of the cavity is a substantially planar surface, preferably wherein both the lower inner surface and the upper inner surface of the cavity are substantially planar.

[0367] Ex165. An aerosol generating device according to example Ex164, wherein the upper inner surface and the lower inner surface of the cavity are arranged in parallel relationship to each other.

[0368] Ex166. An aerosol generating device according to example Ex164, wherein the upper inner surface and the lower inner surface converge along the length of the cavity so that they are slightly closer together at the distal end of the cavity than at the proximal end of the cavity.

[0369] Ex167. An aerosol generating device according to example Ex166, wherein the upper inner surface and the lower inner surface of the cavity converge between the proximal end of the cavity and the distal end of the cavity by 1 degree to 10 degrees, for example, 2 degrees to 8 degrees, for example, 3 degrees to 6 degrees, for example, 4 degrees to 5 degrees.

[0370] Ex168. An aerosol generating device according to any one of Examples Ex164 to Ex167, wherein the lower inner surface and the upper inner surface are movable relative to each other, for example, wherein the lower inner surface and the upper inner surface are configured to pivot relative to each other or move upward and downward relative to each other.

[0371] Ex169. An aerosol generating device according to any one of Examples Ex158 to Ex167, wherein the cavity has a longitudinal dimension or length, a transverse dimension or width, and a depth dimension or height, and wherein the length and the width are greater in magnitude than the height, for example at least twice the magnitude of the height.

[0372] Ex170. An aerosol generating device according to any one of Examples Ex158 to Ex168, wherein the device comprises a heating surface comprising a plurality of individually operable heating zones, for example, 2 individually operable heating zones, or 3 individually operable heating zones, or 4 individually operable heating zones, or 5 individually operable heating zones, or 6 individually operable heating zones.

[0373] Ex171. An aerosol generating device according to example Ex170, wherein the plurality of individually operable heating zones are configured to be operated individually, or simultaneously in any combination of two or more zones.

[0374] Ex172. An aerosol generating device according to example Ex170 or Ex171, wherein the plurality of individually operable heating zones are longitudinally spaced apart within the cavity.

[0375] Ex173. An aerosol generating device according to example Ex170 or Ex171, wherein the plurality of individually operable heating zones are laterally spaced apart within the cavity.

[0376] Ex174. An aerosol generating device according to any one of Examples Ex158 to Ex173, wherein the device comprises one or more resistive heaters, such as one or more resistive heaters integrated into the wall of the cavity.

[0377] Ex175. An aerosol generating device according to any one of Examples Ex158 to Ex174, wherein the device comprises one or more sensors, for example one or more sensors integrated into the wall of the cavity or arranged to generate a fluctuating electromagnetic field in the wall of the cavity or within the cavity.

[0378] Ex176. An aerosol generating device according to example Ex175, wherein the wall of the cavity comprises or consists of a susceptor material.

[0379] Ex177. An aerosol generating device according to any one of Examples Ex158 to Ex176, wherein the device comprises one or more insertable heating elements, and the one or more insertable heating elements are arranged to protrude into the cavity so as to be inserted into the aerosol generating article, for example into the corrugated structure of the aerosol generating article.

[0380] Ex178. An aerosol generating device according to example Ex177, wherein the insertable heating element is a resistive heater, or wherein the heating element is a susceptor.

[0381] Ex179. An aerosol generating system comprising an aerosol generating device according to any one of Examples Ex158 to Ex178 and an aerosol generating article according to any one of Examples Ex128 to Ex157.

[0382] Ex180. A method for manufacturing a planar corrugated aerosol-forming substrate, comprising the following steps:

[0383] providing a first continuous sheet,

[0384] providing a second continuous sheet, at least one of the first sheet and the second sheet being a sheet comprising or consisting of an aerosol-forming material,

[0385] texturing the second continuous sheet using a grooved roller to form a continuous corrugated sheet,

[0386] applying an adhesive to at least one of the continuous corrugated sheet or the first continuous sheet,

[0387] applying the continuous corrugated sheet to a surface of the first continuous sheet to form a continuous aerosol-forming substrate, and

[0388] The continuous aerosol-forming substrate is cut to form the planar corrugated aerosol-forming substrate.

[0389] Ex181. A method for manufacturing a planar corrugated aerosol-forming substrate, comprising the following steps:

[0390] providing a first continuous sheet,

[0391] providing a second continuous sheet, and providing a third continuous sheet,

[0392] at least one of the first sheet, the second continuous sheet, and the second sheet is a sheet comprising or consisting of an aerosol-forming material,

[0393] texturing the second continuous sheet using a grooved roller to form a continuous corrugated sheet,

[0394] applying an adhesive to at least one of the continuous corrugated sheet or the first continuous sheet,

[0395] applying the first side of the continuous corrugated sheet to a surface of the first continuous sheet,

[0396] applying an adhesive to at least one of the continuous corrugated sheet and the third continuous sheet and applying the second side of the continuous corrugated sheet to a surface of the third continuous sheet, thereby forming a continuous aerosol-forming substrate, and

[0397] The continuous aerosol-forming substrate is cut to form the planar corrugated aerosol-forming substrate.

[0398] Ex182. The method according to example Ex180 or Ex181, wherein at least one of the first continuous sheet, the second continuous sheet and the third continuous sheet is a homogenized tobacco sheet.

[0399] Ex183. The method according to any one of Examples Ex180 to Ex182, wherein the binder comprises guar gum.

[0400] Ex184. The method according to any one of Examples Ex180 to Ex183, wherein the binder comprises an aerosol-forming substrate, such as a homogenized tobacco slurry.

[0401] Examples will now be further described with reference to the accompanying drawings, in which:

[0402] Figure 1 is a schematic end view of an aerosol-forming substrate according to an embodiment of the present invention;

[0403] Figure 2 yes Figure 1 Schematic side view of an aerosol-forming substrate;

[0404] Figure 3 yes Figure 1 Schematic plan view of an aerosol-forming substrate;

[0405] Figure 4 Shown as Figure 1 Schematic diagram of a corrugated element used in an aerosol-forming matrix;

[0406] Figure 5 Shown in Figure 1 Schematic diagram of the apparatus used in the manufacture of the aerosol-forming substrate;

[0407] Figure 6 An aerosol generating device according to an embodiment of the present invention is shown, wherein the device is configured to Figure 1 of aerosol-forming matrix bonding;

[0408] Figure 7 Shown Figure 6 An end view of an aerosol generating device;

[0409] Figure 8 is shown with Figure 6 The aerosol generating device is engaged Figure 1 Schematic diagram of the aerosol-forming matrix;

[0410] Figure 9 According to an embodiment of the present invention, Figure 1 a schematic end view of an aerosol-forming article comprising an aerosol-forming substrate;

[0411] Figure 10 yes Figure 9 a perspective view of an aerosol-generating article;

[0412] Figure 11 is a perspective view of an aerosol-generating article according to an embodiment of the present invention;

[0413] Figure 12 is a perspective view of an aerosol-generating article according to an embodiment of the present invention;

[0414] Figure 13 is a perspective view of an aerosol-generating article according to an embodiment of the present invention;

[0415] Figure 14 is a schematic end view of an aerosol-forming substrate according to an embodiment of the present invention;

[0416] Figure 15 is a schematic end view of an aerosol-forming substrate according to an embodiment of the present invention;

[0417] Figure 16 is a schematic end view of an aerosol-forming substrate according to an embodiment of the present invention;

[0418] Figure 17 is a schematic end view of an aerosol-forming substrate according to an embodiment of the present invention;

[0419] Figure 18 According to an embodiment of the present invention, Figure 17 a schematic end view of an aerosol-forming article comprising an aerosol-forming substrate;

[0420] Figure 19 is a schematic end view of an aerosol-forming substrate according to an embodiment of the present invention;

[0421] Figure 20 is a schematic side view of an aerosol-forming substrate according to an embodiment of the present invention;

[0422] Figure 21 is a schematic end view of an aerosol-forming substrate according to an embodiment of the present invention;

[0423] Figure 22 is a schematic end view of an aerosol-forming substrate according to an embodiment of the present invention;

[0424] Figure 23 According to an embodiment of the present invention, Figure 22 a schematic end view of an aerosol-forming article comprising an aerosol-forming substrate;

[0425] Figure 24 is a schematic end view of an aerosol-forming article according to an embodiment of the present invention;

[0426] Figure 25 is a schematic plan cross-sectional view of an aerosol-forming article according to an embodiment of the present invention;

[0427] Figure 26 is a schematic end view of an aerosol-forming substrate according to an embodiment of the present invention;

[0428] Figure 27 is a schematic end view of an aerosol-forming substrate according to an embodiment of the present invention;

[0429] Figure 28 is a schematic plan cross-sectional view of an aerosol-forming article according to an embodiment of the present invention;

[0430] Figure 29 is a schematic plan view of an aerosol-forming article according to an embodiment of the present invention;

[0431] Figure 30 is a schematic side view of an aerosol-forming substrate according to an embodiment of the present invention;

[0432] Figure 31 is a schematic plan view of a planar heater of an aerosol generating device according to an embodiment of the present invention;

[0433] Figure 32 is a schematic plan view of a planar heater of an aerosol generating device according to an embodiment of the present invention;

[0434] Figure 33 is a schematic plan view of a planar heater of an aerosol generating device according to an embodiment of the present invention;

[0435] Figure 34 An aerosol generating device according to an embodiment of the present invention is shown;

[0436] Figure 35 An aerosol generating device according to an embodiment of the present invention is shown;

[0437] Figure 36 An aerosol generating device according to an embodiment of the present invention is shown; and

[0438] Figure 37 An aerosol generating device according to an embodiment of the invention is shown.

[0439] Figure 1 、 2 3 show an end view, a side view and a plan view, respectively, of an aerosol-forming substrate 10 according to an embodiment of the invention. The aerosol-forming substrate 10 comprises a planar upper layer 20, a planar lower layer 30 and an intermediate or separating layer 40 arranged between the upper and lower layers 20, 30.

[0440] The planar upper layer 20 is formed from a paper sheet having a thickness of 300 microns. The planar lower layer 30 is formed from a paper sheet having a thickness of 300 microns. The middle layer 40 is a corrugated element formed from a sheet of corrugated aerosol-forming material 45. A suitable aerosol-forming material may be homogenized tobacco. Thus, the middle layer 40 may be formed from a sheet of corrugated homogenized tobacco material.

[0441] Figure 4 Shown is a corrugated sheet of aerosol-forming material 45. The corrugations have an amplitude 46 of 3 mm and a wavelength 47 of 3 mm. The sheet of aerosol-forming material 45 forming the intermediate layer 40 has a thickness of 150 microns.

[0442] The intersections 51 , 52 between the upper and middle layers and between the lower and middle layers comprise an adhesive joining the respective layers.

[0443] The aerosol-forming substrate had a length extending in the x-dimension of 80 mm, a width extending in the y-dimension of 15 mm and a thickness extending in the z-dimension of 3.6 mm.

[0444] The corrugations of the middle layer 40 form a first set of longitudinal channels 61 defined by the upper layer 20 and the middle layer 40, and a second set of longitudinally extending channels 62 defined by the lower layer 30 and the middle layer 40. The first set of longitudinally extending channels 61 and the second set of longitudinally extending channels 62 extend across the length of the aerosol-forming substrate, between the proximal end 71 and the distal end 72 of the substrate 10. The longitudinally extending channels 61, 62 define an airflow path through the substrate 10. Thus, the airflow path passes over both sides of the sheet of aerosol-forming material 45. The porosity of the aerosol-forming substrate along the airflow path is approximately 90%. This provides an extremely low resistance to draw of less than 5 mmH2O. In fact, the RTD is close to zero.

[0445] The aerosol-forming material 45 can be any suitable sheet of aerosol-forming material. For exemplary purposes, the composition of a suitable aerosol-forming material can be as follows. Percentages are given as weight percentages relative to the product in its final state. The aerosol-forming material can have a moisture content of about 5% to 25%, preferably about 7% to 15%, in the final product state. The aerosol-forming material can also include the following:

[0446] 1. Tobacco leaf; for example, about 15% to 45%, preferably about 20% to 35%, of a tobacco leaf blend comprising at least one of the following tobacco types: flue-cured tobacco; sun-cured tobacco; or oriental tobacco. The tobacco material is ground and graded to a particle size of about 100 to 380 mesh, preferably about 170 to 320 mesh.

[0447] 2. Cellulose fibers; for example, about 1% to 15%, preferably about 3% to 7%, of cellulose fibers having a length of about 10 to 250 μm, preferably about 10 to 120 μm.

[0448] 3. Tobacco fibers; for example, about 5% to 20%, preferably about 7% to 15%, of any tobacco type or blend of tobacco types, as a filler. The tobacco fibers are preferably derived from stems and / or stalks, which are fractionated into fibers having a length of about 10 to 350 μm, preferably about 10 to 180 μm.

[0449] 4. Binder; for example, about 1% to 10%, preferably about 1% to 5%, of a binder, such as any of the common gums or pectins used in the food and beverage (F&B) industry. Preferred binders may be natural pectins (such as fruit, e.g., citrus) or tobacco pectins; guar gum, locust bean gum, such as hydroxyethyl and / or hydroxypropyl derivatives of these; starches, such as modified or derivatized starches; alginates; methyl, ethyl, ethylhydroxymethyl, and carboxymethyl cellulose; dextran; and xanthan gum. A preferred binder is guar gum.

[0450] 5. Aerosol formers; for example, about 5% to 35%, preferably about 10% to 25% aerosol formers. Suitable aerosol formers known in the art include: glycerol; monohydric alcohols such as menthol; polyhydric alcohols such as triethylene glycol; esters of polyhydric alcohols such as glycerol mono-, di-, or triacetate; and aliphatic esters of mono-, di-, or polycarboxylic acids, such as dimethyl esters of these.

[0451] "Tobacco type" means one of different varieties of tobacco, based, for example, on the different curing processes that the tobacco undergoes before being further processed into tobacco products.

[0452] To form the aerosol-forming material 45 , the various components may be mixed together and cast into a sheet having a desired thickness (eg 150 microns). The sheet may then be dried to be suitable for processing to form the aerosol-forming substrate 10 .

[0453] For illustrative purposes, the composition of another aerosol-forming material (which may be suitable as the aerosol-forming material sheet 45 in the above-mentioned specific embodiment) may be as follows. The percentages are given as weight percentages relative to the product in its final state. The aerosol-forming material may include:

[0454] 1. An aerosol former, such as glycerol; e.g. about 10% to 40%, preferably about 20% to 30%.

[0455] 2. Organic fibers; for example, about 10% to 30%, preferably about 15% to 25%, of any plant species suitable and of a purity meeting applicable FDA F&B grade requirements, as commonly available in the market. For example, the organic fibers can be derived from cellulose, cotton, wood, or tea plant species that are byproducts and secondary processing waste from the F&B tea industry. The organic fibers preferably have a length of about 10 to 400 μm, preferably about 10 to 200 μm.

[0456] 3. Organic vegetable glycerin; for example, about 15% to 55%, preferably about 20% to 35% of plant materials such as cloves, echinacea, cumin, ginger, hawthorn berries, elderberries, horse mint, mullein leaves, nettle, plantain, turmeric, yarrow, and compounds of these.

[0457] 4. Organic plant extracts; for example, about 1% to 15%, preferably about 2% to 7%, of any of the previously mentioned plant materials, as well as menthol (dl-menthol, C10H200, 2-isopropyl-5-methylcyclohexanol) and p-menthan-3-ol, which is any secondary alcohol such as a diastereomer of 5-methyl-2-(propan-2-yl)cyclohexan-1-ol, such as obtained from Chaerophyllum macrospermum, Mesosphaerum sidifolium or other related plant species.

[0458] Alternatively, such aerosol-forming materials may also contain about 0.5% to 5%, preferably about 1% to 3%, of plant essential oils, such as palm oil, coconut oil, and wood-based essential oils.

[0459] Figure 5There is shown an apparatus 500 that can be used to manufacture the aerosol-forming substrate 10. Continuous sheets of the three main components of the aerosol-forming substrate are provided, namely a continuous sheet of paper for forming the lower surface 30, a continuous sheet of paper for forming the upper surface 20, and a continuous sheet of aerosol-forming material 45 for forming the corrugated intermediate layer 40.

[0460] The following steps may occur in the manufacture of an aerosol-forming substrate:

[0461] The continuous sheet of aerosol-forming material 45 is conveyed under tension to a pair of corrugating or grooved rollers 511, 512. The corrugating rollers 511, 512 texture the sheet of aerosol-forming material 45 to introduce corrugations of a desired wavelength and amplitude.

[0462] Adhesive 80 is applied to the peaks of the corrugations by a first adhesive applicator 580. The corrugated sheet is then brought into contact with a continuous paper sheet forming the lower layer 30. The lower layer 30 is attached to the corrugated sheet 45 and the combined layers are transferred to a conveyor belt.

[0463] Further adhesive is now applied to the corrugated layer by a second adhesive applicator 581 and the continuous sheet forming the upper layer 20 is introduced and adhered to the corrugated structure. The resulting structure is now a sandwich of corrugated aerosol-forming material 45 between the upper layer 20 and the lower layer 30. The structure is sliced both laterally and transversely by a slicing device 590 to form individual aerosol-forming substrates 10.

[0464] The aerosol-forming substrate may be used alone as an aerosol-generating article, or may be used as a component part of an aerosol-generating article, for example as described further below.

[0465] Figure 6 and 7 An aerosol-generating device 600 configured for use with an aerosol-generating article comprising or consisting of an aerosol-forming substrate 10 is shown. The device 600 is an elongated aerosol-generating device extending between a proximal end 641 and a distal end 642. The device 600 includes a battery 620, a controller 630, and a heater 660 located within a housing 610. The controller 630 controls the supply of power from the battery 620 to the heater 660. A cavity 650 is defined within the device 600, having an opening 653 defined in the proximal end 641 of the device. The opening 653 is rectangular in shape and sized to accommodate the cross-section of the aerosol-forming substrate 10. The cavity includes an upper planar surface 651 and a lower planar surface 652. A heater 660 is located within the lower planar surface 652 to heat the lower surface of an aerosol-forming substrate or article inserted into the cavity 650. An airflow path is configured to allow air to flow from outside the device into the cavity 650.

[0466] Figure 8 Shown with Figure 1 The aerosol-forming substrate 10 is bonded to Figure 6 The device 600 has a substantially uniform surface area. There is virtually no tolerance between the outer surface of the aerosol-forming substrate and the inner surface of the cavity 650. Consequently, there is a close fit between the substrate 10 and the device 600. Since the RTD of the substrate is negligible, the RTD of the system is controlled by the airflow path defined within the device. Once the user has inserted the substrate 10 into the cavity 650, the device can be operated. The heater 660 heats the lower surface of the substrate 10 and, thereby, the aerosol-forming material 45. The volatile components of the aerosol-forming substrate evaporate and condense in the airflow channels 61, 62 to form an aerosol. The user inhales the aerosol by drawing on the proximal end 71 of the aerosol-forming substrate 10. Once the aerosol-forming material 45 has been depleted of volatile components, the substrate is removed from the cavity and disposed of.

[0467] Figure 9 Shown is a cigarette paper 965 wrapped with Figure 1 End view of an aerosol-generating article 901 having an aerosol-forming substrate 10 . Figure 10 , a perspective view of article 901 is shown showing substrate 10, cigarette paper wrap 965 and another tipping paper section 967 wrapped around the article at its proximal end 971. Proximal end 967 may also be referred to as the mouth end and is intended for a user to draw on during use of the article.

[0468] Figure 11 Shown is a perspective view of yet another configuration of an aerosol-generating article 1101. The article 1101 is similar to the article 901 described above, and comprises the same aerosol-forming substrate 10. Figure 11 The article 1101 has cigarette paper 1165 covering the top and bottom planar surfaces of the substrate 10 but not the sides. In addition, a covering layer 1167 of tipping paper is applied to the upper and lower surfaces adjacent to the proximal end 1171 of the article 1101.

[0469] Figure 12 Shown is a perspective view of yet another configuration of an aerosol-generating article 1201. The article 1201 is similar to the article 901 described above, and comprises the same aerosol-forming substrate 10. Figure 12 The article 1201 has cigarette paper 1265 covering the top and bottom planar surfaces of the substrate 10 and one side surface of the substrate. In addition, a half cover layer 1267 of tipping paper is applied adjacent to the proximal end 1271 of the article 1201.

[0470] Figure 13 Shown is a perspective view of yet another configuration of an aerosol-generating article 1301. The article 1301 is similar to the article 901 described above, and comprises the same aerosol-forming substrate 10. Figure 13 The product 1301 has cigarette paper 1365 covering the top and bottom planar surfaces of the substrate 10 but not the sides. Furthermore, a covering layer 1367 of tipping paper is applied to the upper and lower surfaces adjacent to the proximal end 1371 of the product 1301. The product 1301 is wrapped so that its corners are rounded rather than squared. This provides a more pleasant mouthfeel for the user.

[0471] Figure 14 An end view of an aerosol-forming substrate 1410 according to an embodiment of the invention is shown. The aerosol-forming substrate 1410 comprises a planar upper layer 1420, a planar lower layer 1430 and an intermediate or separating layer 1440 arranged between the upper layer 1420 and the lower layer 1430. The intermediate layer is formed from a sheet 1445 of corrugated material. Figure 14 The aerosol-forming substrate 1410 is similar to the aerosol-forming substrate 1410 described above with respect to Figure 1 The aerosol-forming substrate 10 is described, except that the planar upper layer 1420 and the planar lower layer 1430 are formed from sheets of aerosol-forming material (eg homogenised tobacco), and the sheet of corrugated material 1445 does not include aerosol-forming material and is present only for structural purposes.

[0472] Figure 15 An end view of an aerosol-forming substrate 1510 according to an embodiment of the invention is shown. The aerosol-forming substrate 1510 comprises a planar upper layer 1520, a planar lower layer 1530 and an intermediate or separating layer 1540 arranged between the upper and lower layers 1520, 1530. The intermediate layer is formed from a sheet 1545 of corrugated material. Figure 15 The aerosol-forming substrate 1510 is similar to the aerosol-forming substrate 1510 described above with respect to Figure 1 The aerosol-forming substrate 10 is described, except that the planar lower layer 1530 and the sheet of corrugated material 1545 are formed from sheets of aerosol-forming material (eg homogenised tobacco), and the planar upper layer 1520 does not comprise aerosol-forming material.

[0473] Figure 16 An end view of an aerosol-forming substrate 1610 according to an embodiment of the invention is shown. The aerosol-forming substrate 1610 comprises a planar upper layer 1620, a planar lower layer 1630 and an intermediate or separating layer 1640 arranged between the upper and lower layers 1620, 1630. The intermediate layer is formed from a sheet 1645 of corrugated material. Figure 16 The aerosol-forming substrate 1610 is similar to the aerosol-forming substrate 1610 described above with respect to Figure 1 The aerosol-forming substrate 10 is described, except that all of the planar upper layer 1620, the planar lower layer 1630 and the sheet of corrugated material 1645 are formed from a sheet of aerosol-forming material (eg homogenised tobacco).

[0474] Figure 17An end view of an aerosol-forming substrate 1710 according to an embodiment of the invention is shown. The aerosol-forming substrate 1710 comprises a planar lower layer 1430 and a corrugated upper layer 1745. Figure 17 The matrix is similar to Figure 1 1730 and the corrugated upper layer 1745. Either or both of the lower layer 1730 and the corrugated upper layer 1745 may be an aerosol-forming material. Figure 18 Shown wrapped in cigarette paper 1865 includes Figure 17 End view of an aerosol-generating article 1801 having an aerosol-forming substrate 1710 .

[0475] Figure 19 An end view of an aerosol-forming substrate 1910 according to an embodiment of the invention is shown. The aerosol-forming substrate 1910 comprises a planar upper layer 1920, a planar lower layer 1930 and an intermediate or separating layer 1940 arranged between the upper layer 1920 and the lower layer 1930. The intermediate layer is formed from a sheet 1945 of corrugated material. Figure 19 The aerosol-forming substrate 1910 is similar to the aerosol-forming substrate 1910 described above. Figure 1 The aerosol-forming substrate 10 described further includes a top layer 1921 disposed above the upper layer 1920 and a bottom layer 1931 disposed below the lower layer 1930. Either or both of the top layer 1921 and the bottom layer 1931 may be formed from a sheet of material. For example, the sheet of material may be a thermally conductive material (such as aluminum foil), a paper material, a polymeric material, or a porous material (e.g., a tea bag material).

[0476] Figure 20 Shown is a side view of an aerosol-forming substrate 2010 according to an embodiment of the invention.The aerosol-forming substrate 2010 comprises a planar upper layer 2020, a planar lower layer 2030 and an intermediate or separating layer 2040 arranged between the upper and lower layers 2020, 2030. Figure 20 The aerosol forming matrix 2010 is similar to the above Figure 1 The aerosol-forming substrate 10 described above further includes a top layer 2021 disposed toward the distal end 2072 of the upper layer 2020 and a bottom layer 2031 disposed toward the distal end 2072 of the lower layer 2030. The distal portion 2072 may be the portion of the substrate 2010 that is inserted into the aerosol-generating device. Either or both of the top layer 2021 and the bottom layer 2031 may be formed from a sheet or patch of material. For example, the sheet of material may be a thermally conductive material (such as aluminum foil), a paper material, a polymeric material, or a porous material (e.g., tea bag material).

[0477] Figure 21An end view of an aerosol-forming substrate 2110 according to an embodiment of the invention is shown. The aerosol-forming substrate 2110 comprises a planar upper layer 2120, a planar lower layer 2130 and an intermediate or separating layer 2140 arranged between the upper layer 2120 and the lower layer 2130. The intermediate layer is formed from a sheet 2145 of corrugated material. Figure 21 The aerosol-forming substrate 2110 is similar to the aerosol-forming substrate 2110 described above. Figure 1 The depicted aerosol-forming substrate 10 further comprises one or more functional elements 2191, 2192, 2193 positioned within the longitudinally extending channels 2161, 2162 defined by the corrugated sheet 2145. The one or more functional elements may be longitudinal elements, such as flavor threads 2191, which are threads or strips of material impregnated with a flavoring agent, or longitudinal susceptor elements 2193, such as strips of stainless steel or aluminum foil. The one or more functional elements may be discrete elements, such as flavor capsules 2192, e.g., frangible capsules containing aerosol-forming material or flavoring agent that can be broken open by a user prior to consumption of the substrate.

[0478] Figure 22 An end view of an aerosol-forming substrate 2210 according to an embodiment of the present invention is shown. The aerosol-forming substrate 2210 comprises a planar upper layer 2220, a planar lower layer 2230, and an intermediate or separating layer 2240 disposed between the upper layer 2220 and the lower layer 230. The intermediate layer is formed of an upper sheet 2246 and a lower sheet 2247 of corrugated material separated by an intermediate planar layer 2248. Any one or more of the upper layer 2220, the lower layer 2230, the upper corrugated sheet 2246, the lower corrugated sheet 2247, and the intermediate planar sheet 2248 may be formed of an aerosol-forming material. Figure 23 Shown is a cigarette paper 2365 wrapped with Figure 22 End view of an aerosol-generating article 2301 having an aerosol-forming substrate 2210 .

[0479] Figure 24 Shown is a cigarette paper 2365 wrapped with a cigarette paper 2365 including Figure 1 An end view of an aerosol-generating article 2401 depicting two aerosol-forming substrates 10. The aerosol-forming substrates 10 are arranged laterally within a cigarette paper 2465. The substrates may be of different compositions, thereby allowing different flavour combinations to be easily produced.

[0480] Figure 25A plan cross-sectional view of an aerosol-generating article 2501 assembled within a packaging 2565 is shown, the aerosol-generating article comprising an aerosol-forming substrate 2510 and a structural component 2511 having substantially the same cross-sectional dimensions as the aerosol-forming substrate 2510. The aerosol-forming substrate 2510 is positioned towards the distal end 2572 of the article, and the structural component 2511 is positioned towards the proximal end 2571 of the article. An airflow path extends through the article 2501 between the distal end 2572 and the proximal end 2571. The aerosol-forming substrate is a substrate as described herein, for example with respect to Figure 1 The structural member 2511 may be another aerosol-generating substrate, such as a substrate as described herein. The structural member may not include an aerosol-forming material. The structural member may be a tube, such as a rectangular cross-section tube. The structural member may be a corrugated cardboard member.

[0481] Figure 26 An end view of an aerosol-forming substrate 2610 according to an embodiment of the invention is shown. The aerosol-forming substrate 2610 comprises a planar upper layer 2620, a planar lower layer 2630 and an intermediate or separating layer 2640 arranged between the upper layer 2620 and the lower layer 2630. The intermediate layer is formed from a sheet 2645 of corrugated material. Figure 26 The aerosol-forming substrate 2610 is similar to the aerosol-forming substrate 2610 described above with respect to Figure 1 The depicted aerosol-forming substrate 10 further comprises a porous material 2681 located within the longitudinally extending channels 2661, 2662 defined by the corrugated sheet 2645. The porous material 2681 may control the RTD of the substrate. The porous material 2681 may comprise an aerosol-forming material, for example may be impregnated with a liquid aerosol-forming material.

[0482] Figure 27 An end view of an aerosol-forming substrate 2710 according to an embodiment of the invention is shown. The aerosol-forming substrate 2710 comprises a planar upper layer 2720, a planar lower layer 2730 and an intermediate or separating layer 2740 arranged between the upper layer 2720 and the lower layer 2730. The intermediate layer is formed from a sheet 2745 of corrugated material. Figure 27 The aerosol-forming substrate 2710 is similar to the aerosol-forming substrate 2710 described above with respect to Figure 1 The depicted aerosol-forming substrate 10 further comprises a mesh 2785 spanning the proximal end 2771 of the substrate 2710. The mesh may help prevent particles of the substrate from being inhaled by a user.

[0483] Figure 28A plan cross-sectional view of an aerosol-generating article 2801 is shown comprising an aerosol-forming substrate 2810, a structural component 2811 having substantially the same cross-sectional dimensions as the aerosol-forming substrate 2810, and a mouthpiece filter 2812, all coaxially aligned and assembled within a wrapper 2865. The aerosol-forming substrate 2810 is positioned towards a distal end 2872 of the article, the structural component 2811 is located proximally relative to the aerosol-forming substrate, and the mouthpiece filter 2812 is located at a proximal end 2871 of the article. An airflow path extends through the article 2801 between the distal end 2872 and the proximal end 2871. The aerosol-forming substrate is a substrate as described herein, for example with respect to Figure 1 The structural member 2811 may be another aerosol-generating substrate, such as a substrate as described herein. The structural member may not include an aerosol-forming material. The structural member may be a tube, such as a tube with a rectangular cross-section. The structural member may be a corrugated cardboard member. The mouthpiece filter 2812 may be formed from cellulose acetate tow.

[0484] Figure 29 A plan view of an aerosol-generating article 2901 is shown, comprising an aerosol-forming substrate (not visible) contained within a cigarette paper wrapper 2965. The wrapper 2965 includes an air inlet aperture 2995 to allow air to pass through the wrapper 2965 into the article 2910. In a preferred embodiment, the air inlet aperture can be centrally aligned on one or both of the top and bottom portions of the article. The article can include two aerosol-forming substrates, one positioned toward the distal end 2972 of the article and one positioned toward the proximal end 2971 of the article. The article can be a dual-use article designed so that the two aerosol-forming substrates are consumed independently. For example, the distal end can be inserted into an aerosol-generating device and the distal aerosol-forming substrate consumed, with the user inhaling on the proximal end of the article. The article can then be inverted so that the proximal end is inserted into the aerosol-generating device and the proximal aerosol-forming substrate consumed, with the user inhaling on the distal end of the article. In both cases, the air inlet holes may allow airflow into the article during consumption.

[0485] Figure 30 30. The aerosol-forming substrate 3010 is shown in side view according to an embodiment of the present invention. The aerosol-forming substrate 3010 comprises a planar upper layer 3020, a planar lower layer 3030 and an intermediate or separating layer 3040 arranged between the upper layer 3020 and the lower layer 3030. The intermediate layer is formed from a sheet of corrugated material 3045. The sheet of corrugated material 3045 is a highly perforated sheet or web of material, thereby allowing airflow through the substrate in a direction perpendicular to the direction of the corrugations (the airflow is caused by the corrugation). Figure 30 (indicated by the arrow in the figure).

[0486] Figure 31 is a schematic plan view of a planar heater 3151 suitable for use in an aerosol generating device according to an embodiment of the present invention, the aerosol generating device being, for example, about Figure 6 The aerosol generating device 600 described herein. The planar heater 3151 may form a lower surface of the cavity of the aerosol generating device and is configured to heat an aerosol-forming substrate as described herein. Figure 31 In a specific example, the planar heater 3151 includes a first heating zone 3152 located at the proximal end 3171 of the heater and a second heating zone 3153 located at the distal end 3172 of the heater. The first heating zone 3152 and the second heating zone 3153 may be formed by separate resistive heater tracks. Alternatively, the heater may be an induction heater, and the first and second heating zones may be affected by separate induction coils acting on a susceptor material in the first or second zone. The first and second heating zones may be operated independently or together and may allow for sequential heating of portions of the aerosol-forming substrate.

[0487] Figure 32 is a schematic plan view of a planar heater 3251 suitable for use in an aerosol generating device according to an embodiment of the present invention, the aerosol generating device being, for example, Figure 6 The aerosol generating device 600 described herein. The planar heater 3251 may form a lower surface of the cavity of the aerosol generating device and is configured to heat an aerosol-forming substrate as described herein. Figure 32 In the specific example of , the planar heater 3251 includes a first heating zone 3252, a second heating zone 3253, a third heating zone 3254, and a fourth heating zone 3255 spaced continuously between a proximal end 3271 of the heater and a distal end 3272 of the heater. The different heating zones may be formed by separate resistive heater tracks. Alternatively, the heater may be an induction heater, and the heating zones may be affected by separate induction coils acting on susceptor material in the first zone or the second zone. The heating zones may be operated independently or together, and may allow for sequential heating of portions of the aerosol-forming substrate.

[0488] Figure 33 is a schematic plan view of a planar heater 3351 suitable for use in an aerosol generating device according to an embodiment of the present invention, the aerosol generating device being, for example, about Figure 6 The aerosol generating device 600 described herein. The planar heater 3351 may form a lower surface of the cavity of the aerosol generating device and is configured to heat an aerosol-forming substrate as described herein. Figure 33In the specific example of , the planar heater 3351 includes a first heating zone 3352, a second heating zone 3353, a third heating zone 3354, and a fourth heating zone 3355 spaced continuously between a first lateral edge 3373 of the heater and a second lateral edge 3374 of the heater. The different heating zones may be formed by separate resistive heater tracks. Alternatively, the heater may be an induction heater, and the heating zones may be affected by separate induction coils acting on susceptor material in the first zone or the second zone. The heating zones may be operated independently or together, and may allow for sequential heating of portions of the aerosol-forming substrate.

[0489] Figure 34 An aerosol generating device 3400 configured for use with an aerosol generating article comprising or consisting of an aerosol-forming substrate as described herein is shown. The device 3400 is similar to the aerosol generating article described above with respect to Figure 6 The device 600 is described. A cavity 3450 is defined in the device 3400, the cavity 3450 having an opening 3453 defined in the proximal end 3441 of the device. The opening 3453 is sized to accommodate a cross-section of an aerosol-forming substrate. The cavity includes an upper planar surface 3451 and a lower planar surface 3452. Heaters 3460 and 3461 are located in both the lower planar surface 3452 and the upper planar surface to heat both the upper and lower surfaces of an aerosol-forming substrate or article inserted into the cavity 3450.

[0490] Figure 35 An aerosol generating device 3500 is shown configured for use with an aerosol generating article comprising or consisting of an aerosol-forming substrate as described herein. The device 3500 is similar to the aerosol generating article described above with respect to Figure 6 Device 600 is described. A cavity 3550 is defined within device 3500, the cavity 3550 having an opening 3553 defined in the proximal end 3541 of the device. Opening 3553 is sized to accommodate a cross-section of an aerosol-forming substrate. The cavity includes an upper planar surface 3551 and a lower planar surface 3552. Susceptors 3560 and 3561 are both located within lower planar surface 3552 and protrude into the cavity. Protruding susceptor 3561 is in the form of a pin or strip configured to penetrate a portion of an aerosol-generating article and internally heat the article. An induction coil 3463 surrounds the cavity and is configured to generate a fluctuating magnetic field to heat susceptors 3560 and 3561.

[0491] Figure 36An aerosol-generating device 3600 configured for use with an aerosol-generating article comprising or consisting of an aerosol-forming substrate as described herein is shown. The device 3600 is similar to the aerosol-generating article described above with respect to Figure 6 36. A cavity 3650 is defined within the device 3600, the cavity 3650 having an opening 3653 defined in the proximal end 3641 of the device. The opening 3653 is sized to accommodate a cross-section of an aerosol-forming substrate. The cavity includes an upper planar surface 3651 and a lower planar surface 3652. A susceptor 3660 is positioned within the lower planar surface 3652. A planar induction coil 3663 is positioned below the cavity and is configured to generate a fluctuating magnetic field to heat the susceptor 3660.

[0492] Figure 37 An aerosol-generating device 3700 configured for use with an aerosol-generating article 3701 comprising or consisting of an aerosol-forming substrate as described herein is shown. The device 3700 is similar to the aerosol-generating article 3701 described above with respect to Figure 6 The device 600 described herein comprises a cavity 3750 defined in the device 3700, the cavity 3750 having an opening 3753 defined in the proximal end 3741 of the device. The opening 3753 is sized to accommodate a cross-section of an aerosol-forming substrate. The cavity comprises an upper planar surface 3751 and a lower planar surface 3752. The upper planar surface 3751 and the lower planar surface 3752 are non-parallel and converge slightly between the opening and the distal end 3754 of the cavity. This convergence allows the planar surfaces of the cavity to grip the aerosol-generating article 3701 when the aerosol-generating article is inserted into the cavity for consumption.

[0493] For the purposes of this specification and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, etc. should be understood to be modified by the term "about" in all cases. Moreover, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein that may or may not be specifically listed herein. Therefore, in this context, the number A is understood to be A±10%A. In this context, the number A can be regarded as including the numerical value within the general standard error for the measurement of the property modified by the number A. In certain cases used in the appended claims, the number A may deviate from the percentages listed above, provided that the amount of A deviation does not substantially affect the basic characteristics and novel features of the invention claimed. Moreover, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein that may or may not be specifically listed herein.

Claims

1. An aerosol-forming substrate comprising an aerosol-forming material for generating an aerosol, the aerosol-forming substrate having a base defined by an x dimension and a y dimension, and a height defined by a z dimension, wherein an airflow path is defined through the aerosol-forming substrate in the x / y plane from one side of the aerosol-forming substrate to the other side of the aerosol-forming substrate, wherein the resistance to draw (RTD) of the substrate along the airflow path is less than 20 mm H2O, and wherein the substrate comprises a corrugated layer or a corrugated element.

2. An aerosol-forming substrate according to claim 1, wherein the RTD is less than 10 mm H2O, such as less than 8 mm H2O, such as less than 6 mm H2O, such as less than 4 mm H2O, or preferably less than 2 mm H2O.

3. An aerosol-forming substrate according to claim 1 or 2, wherein the substrate comprises an upper layer and a lower layer, wherein the airflow path is defined between the upper layer and the lower layer, for example wherein a plurality of channels are defined through the aerosol-forming substrate between the upper layer and the lower layer.

4. An aerosol-forming substrate according to claim 3, wherein an intermediate or separating layer is located between the upper layer and the lower layer, and the airflow path is defined in the intermediate layer.

5. An aerosol-forming substrate according to claim 4, wherein the intermediate layer comprises or consists of the corrugated layer or element, preferably wherein the airflow path is defined through the substrate by channels formed by the longitudinally extending corrugations of the corrugated layer or element.

6. An aerosol-forming substrate according to claim 5, wherein the airflow direction extends between the proximal end of the substrate and the distal end of the substrate, and wherein the airflow path is defined by at least one corrugated element, the ridges and valleys of the at least one corrugated element being aligned substantially parallel to the airflow direction.

7. An aerosol-forming substrate according to claim 6, wherein the aerosol-forming substrate includes a first corrugated element located at or toward the proximal end and a second corrugated element located at or toward the distal end, for example, wherein the first corrugated element and the second corrugated element are arranged in a lateral end-to-end relationship with each other between the upper layer and the lower layer, and each corrugated element is aligned substantially parallel to the airflow direction.

8. An aerosol-forming substrate according to any preceding claim, comprising an upper layer, a lower layer and an intermediate layer arranged between the upper layer and the lower layer, wherein at least one of the upper layer, the lower layer and the intermediate layer comprises an aerosol-forming material or consists of an aerosol-forming material, for example, wherein at least two of the upper layer, the lower layer and the intermediate layer comprise an aerosol-forming material or consist of an aerosol-forming material, for example, wherein all three of the upper layer, the lower layer and the intermediate layer comprise an aerosol-forming material or consist of an aerosol-forming material.

9. An aerosol-forming substrate according to any preceding claim, wherein the aerosol-forming material is a homogenised tobacco material, for example wherein any of the upper layer, the lower layer and the middle layer comprises or consists of a sheet of homogenised tobacco material.

10. An aerosol-forming substrate according to any preceding claim, comprising an upper layer, a lower layer and an intermediate layer arranged between the upper and lower layers, wherein the intermediate layer is fixed relative to at least one of the upper and lower layers by an adhesive, for example wherein the adhesive comprises guar gum, optionally wherein the adhesive comprises an aerosol-forming material, such as homogenised tobacco slurry.

11. An aerosol-forming substrate according to any preceding claim, wherein the aerosol-forming material is a first aerosol-forming material, and the substrate comprises the first aerosol-forming material and a second aerosol-forming material, the second aerosol-forming material being, for example, a second aerosol-forming material different from the first aerosol-forming material.

12. An aerosol-forming substrate according to any preceding claim, comprising an upper layer, a lower layer and an intermediate layer arranged between the upper layer and the lower layer, wherein the intermediate layer comprises a plurality of corrugated elements, wherein two or more of the plurality of corrugated elements are arranged in a vertical relationship to each other between the upper layer and the lower layer.

13. An aerosol-forming substrate according to any preceding claim, comprising one or more susceptor materials, for example wherein the one or more susceptor materials are included within the aerosol-forming material of the aerosol-forming substrate and / or wherein the one or more susceptor materials are included within the aerosol-forming substrate as one or more susceptor material strips, threads or filaments, for example one or more susceptor material strips, threads or filaments located within the airflow path of the aerosol-forming substrate, and / or wherein the one or more susceptor materials are included within the aerosol-forming substrate as one or more susceptor material sheets or layers, for example one or more susceptor material sheets or layers covering an outer portion of the aerosol-forming substrate or forming a structural component of the aerosol-forming substrate.

14. An aerosol-generating article for use with an aerosol-generating device to generate an inhalable aerosol, the aerosol-generating article consisting of or comprising an aerosol-forming substrate according to any one of claims 1 to 13.

15. An aerosol-generating article according to claim 14, wherein the plurality of components comprising the aerosol-forming substrate are assembled within an outer packaging or housing.

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