Aerosol-generating article

Abstract

An aerosol-generating article for use with an aerosol-generating device to generate an inhalable aerosol is provided. The aerosol-generating article includes a planar upper layer and a planar lower layer vertically spaced apart from each other by a separation height defined in the z-direction. The aerosol-generating article also includes an air inlet, an air outlet, and an airflow passage extending between the air inlet and the air outlet. The airflow passage is defined between the planar upper layer and the planar lower layer and has a width defined in the y-direction, where the width of the airflow passage is greater than 1 mm and the separation height is less than 5 mm.

Description

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

[0002] 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.

[0003] Studies have shown that in typical aerosol-generating articles comprising a stick of an aerosol-forming substrate, a substantial portion of the stick of the aerosol-forming substrate may not be sufficiently heated during use to form an aerosol. This is undesirable because this portion of the stick of the 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 stick of the aerosol-forming substrate is heated internally or externally.

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

[0005] According to the present disclosure, an aerosol-generating article may be provided, comprising an aerosol-forming substrate for generating an aerosol, the aerosol-generating article being a planar aerosol-generating article having a base defined by a length extending in the x-direction, a width extending in the y-direction, and a height extending in the z-direction. The aerosol-generating article may include a planar upper layer and a planar lower layer vertically spaced apart from each other by a separation height defined in the z-direction. The aerosol-generating article may include an air inlet, an air outlet, and an airflow passage extending between the air inlet and the air outlet, the airflow passage may be defined between the planar upper layer and the planar lower layer and have a width defined in the y-direction. The width of the airflow passage may be greater than 1 mm, and the separation height may be less than 5 mm.

[0006] According to the present disclosure, an aerosol-generating article for use with an aerosol-generating device to generate an inhalable aerosol may be provided. The aerosol-generating article may include a planar upper layer and a planar lower layer vertically spaced apart from each other by a separation height defined in the z-direction. The aerosol-generating article may include an air inlet, an air outlet, and an airflow path extending between the air inlet and the air outlet, the airflow path may be defined between the planar upper layer and the planar lower layer. The airflow path may have a width defined in the y-direction. The width of the airflow path may be greater than 1 mm, and the separation height may be less than 5 mm.

[0007] The aerosol-generating articles of the present disclosure may be substantially flat and thin. They may be essentially planar and have a small separation between a planar upper layer and a planar lower layer. Providing a substantially flat and thin aerosol-generating article provides for rapid and efficient heating of the aerosol-forming substrate in the aerosol-generating article and improved uniformity in through-thickness heating. Advantageously, the maximum distance between a portion of the aerosol-forming substrate and a heater used to heat the aerosol-generating article is reduced, and the aerosol-forming material in the aerosol-generating article can be heated more quickly.

[0008] Advantageously, the width of the airflow passageway is relatively large to allow sufficient airflow through the aerosol-generating article despite the article being generally flat and thin (e.g., the aerosol-generating article has a small separation between a planar upper layer and a planar lower layer). Providing a generally wide airflow passageway may also allow a user to comfortably inhale the aerosol-generating article during use, despite the small separation height of the aerosol-generating article, and may provide a desired amount of aerosol to the user. In particular, a wide airflow passageway may allow air to flow relatively slowly through the aerosol-generating article, thereby providing improved contact between the airflow and the aerosol-forming substrate of the aerosol-generating article, enhanced mixing of the generated aerosol and air in the airflow passageway, and improved aerosolization.

[0009] The air flow passage may have a passage height defined in the z-direction.The passage height may be equal to the separation height.

[0010] The planar upper layer and the planar lower layer may be parallel.

[0011] The separation height may be the maximum vertical distance between a planar upper layer and a planar lower layer.

[0012] Preferably, the separation height is less than 4 mm, such as less than 3 mm, such as less than 2 mm, such as less than 1 mm.

[0013] The separation height may be greater than 0.1 mm, such as greater than 0.2 mm, such as greater than 0.5 mm.

[0014] According to the present disclosure, an aerosol-generating article may be provided, comprising an aerosol-forming substrate for generating an aerosol, the aerosol-generating article 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.

[0015] The planar upper layer may include an upper outer surface, and the planar lower layer may include a lower outer surface. The upper outer surface may be a substantially planar upper surface, and the lower outer surface of the planar lower layer may be a planar lower surface of the aerosol-generating article. The upper outer surface and the lower outer surface are vertically spaced apart by a surface-to-surface height, wherein the surface-to-surface height is less than 5 mm.

[0016] Preferably, the surface-to-surface height is less than 4.1 mm, such as less than 3.1 mm, such as less than 2.1 mm, such as less than 1.1 mm.

[0017] Preferably, the width of the air flow passage is greater than 1.2 mm, such as greater than 1.5 mm, such as greater than 2 mm.

[0018] The width of the air flow passage may be less than 3 mm, such as less than 2.8 mm, such as less than 2.5 mm.

[0019] Preferably, the air flow passage may have a cross-sectional area defined in the yz direction, wherein the cross-sectional area of ​​the air flow passage is greater than 0.1 square millimeters and less than 15 square millimeters, such as greater than 1 square millimeter and less than 12.5 square millimeters.

[0020] The air flow passage may have a length defined in the x-direction, wherein the length is greater than 15 mm and less than 40 mm, such as greater than 20 mm and less than 30 mm, such as 26 mm.

[0021] The width of the airflow passage may be consistent along the length of the airflow passage.

[0022] The air flow passage may have a volume greater than 1.5 cubic millimeters, less than 600 cubic millimeters, greater than 15 cubic millimeters and less than 40 cubic millimeters, greater than 20 and less than 30, less than 187.5 cubic millimeters, or less than 450 cubic millimeters.

[0023] The separation height may be no more than 5 times the width of the air flow passage, such as no more than 4 times the width of the air flow passage, such as no more than 3 times the width of the air flow passage.

[0024] The width of the air flow passage may be the average width of the air flow passage defined in the y-direction across the separation height.

[0025] The width of the air flow path may be uniform along the separation height, for example, the cross section of the air flow path defined in the y and z directions may be square or rectangular.

[0026] The aerosol-generating article may have an article width defined in the y-direction, wherein the width of the airflow passage is at least 0.1 times the article width, such as at least 0.2 times the article width, such as at least 0.3 times the article width.

[0027] The aerosol-generating article may comprise a single airflow pathway. Alternatively, the aerosol-generating article may comprise two or more airflow pathways. For example, the aerosol-generating article may comprise a plurality of airflow pathways.

[0028] The air flow passage may be formed by a single air flow channel extending between the air inlet and the air outlet.

[0029] Alternatively, a plurality of discrete air flow channels may together form an air flow pathway, wherein each channel extends from a channel air inlet to a channel air outlet.

[0030] Each channel air inlet of the plurality of discrete airflow channels may together form an air inlet of the aerosol-generating article. Each of the channel air outlets of the plurality of discrete airflow channels may together form an air outlet of the aerosol-generating article.

[0031] Each discrete airflow channel may have a channel width, wherein the width of the airflow passage is a cumulative width that is the sum of each of the channel widths.

[0032] Each discrete airflow channel may have a channel interior volume, wherein the volume of the airflow passageway is a cumulative volume that is the sum of each of the channel interior volumes.

[0033] Preferably, the planar upper layer, the planar lower layer or both the planar upper layer and the planar lower layer comprise an aerosol-forming substrate.

[0034] Aerosol-generating articles according to the present disclosure may preferably be substantially flat articles or substantially planar articles. Such articles have a large base area relative to the volume of the article. 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 for a smaller temperature gradient or temperature difference across the height of the aerosol-generating article during heating. For example, where the base of the aerosol-generating article is in contact with and heated by the planar heater, if the spacing or height between the base and the upper surface is small, there may be a smaller temperature difference between the base and the upper surface opposite the base. Advantageously, this can allow a larger proportion of the aerosol-forming substrate of the aerosol-generating article to be heated to a temperature at which the aerosol is released, 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 sufficiently heat the aerosol-forming substrate to release the aerosol.

[0035] The aerosol-generating article according to any aspect disclosed herein may have an airflow path extending through the aerosol-generating article. The airflow path may be defined as passing through an air inlet, an air outlet, and an airflow path. The aerosol-generating article may have an airflow path defined as passing through the aerosol-generating article from one side of the aerosol-generating article to the other side of the aerosol-generating article in the x / y plane. Preferably, the aerosol-generating article has a resistance to draw (RTD) of less than 20 mm H2O in the direction of the airflow path, preferably in the direction of the airflow path.

[0036] The aerosol-generating article may have a resistance to draw (RTD) of less than 10 mm HO in the direction of the airflow path, preferably in the direction of the airflow passage. Preferably, the aerosol-generating article has an RTD of less than 20 mm HO, for example less than 10 mm HO, in at least one direction in the x / y plane of the aerosol-generating article. Aerosol-generating articles with low-resistance airflow paths may allow for superior airflow management and allow the aerosol to be more efficiently extracted from the aerosol-generating article and directed to the user.

[0037] 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-generating article. The terms "pressure drop" or "draw resistance" of a component or article may also refer to "resistance to draw." Such terms generally refer to measurements made in accordance with ISO 6565-2015, and are typically tested 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.

[0038] The aerosol-generating article according to any aspect disclosed herein may comprise a substantially planar upper surface and a lower surface. The vertical separation between the substantially planar upper surface and the lower surface may define the height (e.g., the z dimension, such as the surface-to-surface height) of the aerosol-generating article. The airflow channel may be defined between the substantially planar upper surface and the lower surface. The height of the aerosol-generating article may be less than 5 mm, such as between 1.5 mm and 5 mm, such as between 1.5 mm and 4 mm, such as between 1.5 mm and 3 mm, such as between 1.5 mm and 2 mm. One or both of the substantially planar upper surface and the lower surface may comprise an aerosol-forming substrate. The aerosol-generating article may comprise an upper layer and a lower layer, at least one of the upper layer and the lower layer comprising or consisting of an aerosol-forming substrate, the upper layer forming the substantially planar upper surface, and the lower layer forming the substantially planar lower surface.

[0039] The aerosol-generating article may further comprise an intermediate layer disposed between the first planar layer and the second planar layer.

[0040] Preferably, an air flow passage is defined through the intermediate layer.

[0041] The intermediate layer may comprise or consist of corrugated elements or a corrugated layer.

[0042] The corrugations of a corrugated element or layer can be defined by a corrugation wavelength and a corrugation amplitude. The corrugation wavelength can 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 can be between 0.1 mm and 5 mm, for example, between 0.2 mm and 4 mm, for example, between 0.5 mm and 3 mm, for example, between 0.7 mm and 2 mm, for example, about 1 mm, about 1.2 mm, or about 1.5 mm. The corrugation amplitude is the same as the thickness (e.g., in the z dimension) of the corrugated element or layer.

[0043] The separation height may be equal to the corrugation amplitude.

[0044] The longitudinal channels formed by the longitudinally extending corrugations of the corrugated element or corrugated layer may extend in a planar direction of the first and second planar layers.The longitudinal channels may extend together in the x / y plane between the distal end of the aerosol-generating article and the proximal end of the aerosol-generating article.

[0045] A plurality of longitudinally extending channels may be defined by the corrugations between the first planar layer and the corrugated layer and between the corrugated layer and the second planar layer.

[0046] The plurality of longitudinally extending channels preferably extend in the x-direction.

[0047] A plurality of longitudinally extending channels preferably extend between the air inlet and the air outlet.

[0048] Each longitudinally extending channel of the plurality of longitudinally extending channels may be from a discrete airflow channel, such that the aerosol-forming article may comprise a plurality of discrete airflow channels.

[0049] The plurality of discrete airflow channels may together form an airflow pathway, wherein each channel extends from a channel air inlet to a channel air outlet. Each channel air inlet of the plurality of discrete airflow channels may together form an air inlet of the aerosol-generating article. Each of the channel air outlets of the plurality of discrete airflow channels may together form an air outlet of the aerosol-generating article.

[0050] Each discrete airflow channel may have a channel width, wherein the width of the airflow passage is a cumulative width that is the sum of each of the channel widths.

[0051] Each discrete airflow channel may have a channel interior volume, wherein the volume of the airflow passageway is a cumulative volume that is the sum of each of the channel interior volumes.

[0052] The channel width of each discrete air flow channel in the plurality of discrete air flow channels may be an average width of the channel.The channel width of each discrete air flow channel in the plurality of discrete air flow channels may be half a wavelength of the channel.

[0053] The channel width of each discrete airflow channel in the plurality of discrete airflow channels may be uniform along the length of each discrete airflow channel.

[0054] Each discrete airflow channel of the plurality of discrete airflow channels may have a channel cross-sectional area defined in the zy direction.The airflow passage cross-sectional area may be a cumulative cross-sectional area of ​​all channel cross-sectional areas of each discrete airflow channel of the plurality of discrete airflow channels.

[0055] Each discrete airflow channel in the plurality of discrete airflow channels may have a channel length. The channel length may be equal to a length of the airflow passage defined in the x-direction.

[0056] The corrugated layer may be a sheet of corrugated material.

[0057] At least one of the first planar layer, the second planar layer and the corrugated layer may comprise or consist of an aerosol-forming material.The aerosol-forming material may be a homogenised tobacco material.

[0058] One or more of the first planar layer, the intermediate layer, and the second planar layer may comprise or consist of an aerosol-forming material.

[0059] One or both of the first planar layer and the second planar layer may comprise or consist of an aerosol-forming material, the first planar layer being free of an aerosol-forming material.

[0060] The middle layer may comprise or consist of an aerosol-forming material, and the first and second planar layers may be free of aerosol-forming material.

[0061] The middle layer may be fixed relative to at least one of the upper layer and the lower layer by an adhesive. For example, the adhesive may include guar gum. The adhesive may include an aerosol-forming material, such as a homogenized tobacco slurry.

[0062] A porous element may be located in at least one of the longitudinally extending channels.

[0063] The use of corrugated structures in aerosol-generating articles can advantageously allow the production of aerosol-generating articles having very low RTDs while still being rigid enough for handling by the user. Furthermore, the use of corrugated structures can allow the production of low-density, low-RTD aerosol-generating articles using high-speed production methods similar to those used to produce corrugated cardboard.

[0064] The width of the air flow passage may be the average width of the air flow passage defined in the y-direction across the separation height.

[0065] According to the present disclosure, an aerosol-generating article may be provided, comprising a first planar layer, a second planar layer, and a corrugated layer disposed between the first planar layer and the second planar layer. The first planar layer may be a planar upper layer as described herein, and the planar lower layer may be a second planar layer as described herein. At least one of the first planar layer, the second planar layer, and the corrugated layer may comprise or consist of an aerosol-forming substrate. The first planar layer may be a planar upper layer, and the second planar layer may be a planar lower layer. The planar upper layer and the planar lower layer may be vertically spaced apart from each other by a separation height defined in the z-direction. The aerosol-generating article may comprise an air inlet, an air outlet, and an air flow path extending between the air inlet and the air outlet, the air flow path may be defined between the planar upper layer and the planar lower layer and have a width defined in the y-direction. The width of the air flow path may be greater than 1 mm, and the separation height may be less than 5 mm.

[0066] The use of a corrugated structure, such as a corrugated layer, in an aerosol-generating article can advantageously allow the production of an aerosol-generating article having a very low RTD while still being sufficiently rigid for handling by the user. Furthermore, the use of a corrugated structure can allow the production of low-density, low-RTD aerosol-generating articles using high-speed production methods similar to those used to produce corrugated cardboard.

[0067] The aerosol-generating article may further comprise a planar frame positioned between the first planar layer and the second planar layer. The upper surface may define an outer surface of the first planar layer, and the lower surface may define an outer surface of the second planar layer. The planar frame may define a cavity. An airflow path may be defined through the aerosol-generating article in the x / y plane, the airflow path extending through the cavity.

[0068] The cavity may have a height defined in the z-direction equal to the separation height and the airflow passage height.

[0069] The airflow path may be at least partially defined by the frame. The frame may include an inlet airflow channel and an outlet airflow channel, the inlet airflow channel being configured to allow air to flow into the cavity, and the outlet airflow channel being configured to allow air to flow out of the cavity. The inlet airflow channel and the outlet airflow channel may be defined on opposite ends of the frame. The inlet airflow channel may be defined in a first width edge of the frame, and the outlet airflow channel may be defined in a second width edge of the frame. The inlet airflow channel may include an air inlet, and the outlet airflow channel may include an air outlet. The airflow path may be defined between the air inlet and the air outlet and extend through the cavity.

[0070] The air flow passage may be formed by a single air flow channel comprising a cavity and extending between the air inlet and the air outlet.

[0071] The cavity may have a width defined in the y-direction equal to the width of the airflow passageway.

[0072] The cavity may have a length defined in the x-direction equal to the length of the airflow path.

[0073] The planar upper layer, the planar lower layer, or both the planar upper layer and the planar lower layer may comprise an aerosol-forming substrate.

[0074] According to the present disclosure, an aerosol-generating article may be provided, comprising: a first planar outer surface; a second planar outer surface; a cavity; a frame positioned between the first planar outer surface and the second planar outer surface, the frame at least partially defining the cavity; an aerosol-forming substrate positioned between the first planar outer surface and the second planar outer surface; and an air inlet and an air outlet; and an air flow passage extending through the cavity between the air inlet and the air outlet. The first planar outer surface and the second planar outer surface may be vertically spaced apart from each other by a separation height defined in the z-direction. The air flow passage may have a width defined in the y-direction. The width of the air flow passage may be greater than 1 mm, and the separation height may be less than 5 mm.

[0075] The frame may comprise a peripheral wall that at least partially defines or surrounds the cavity.The frame may comprise a peripheral wall that fully defines or surrounds the cavity.

[0076] The aerosol-generating article may comprise a first planar outer layer and a second planar outer layer, wherein the first planar outer layer forms a first planar outer surface and the second planar outer layer forms a second planar outer surface. Optionally, at least one of the first planar outer layer, the second planar outer layer and the frame may comprise or consist of an aerosol-forming substrate.

[0077] The cavity may be substantially empty.

[0078] An aerosol-forming substrate may be positioned within the cavity.

[0079] The corrugated layer may be positioned within the cavity.

[0080] The aerosol-generating article of any aspect of the present disclosure may have a length (e.g., x-dimension) between 10 mm and 100 mm, or 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.

[0081] The aerosol-generating article may have a width (e.g. y dimension) of 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.

[0082] The aerosol-generating article may have a height (e.g., z dimension) 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.

[0083] When viewed in plan, the aerosol-generating article of any aspect of the present disclosure may have a shape that defines a polygon, a quadrilateral (e.g., a rectangle or square), an oval, or a circle, or a combination thereof. Where the aerosol-generating article comprises a substantially planar upper surface and a lower surface, when viewed in plan, one or both of the upper and lower surfaces may have a shape that defines a polygon, a quadrilateral (e.g., a rectangle or square), an oval, a circle, or a combination thereof. When viewed in plan, the perimeter of the aerosol-generating article may be formed by a plurality of straight sides, a plurality of curved sides, or a combination of straight and curved sides. Where the aerosol-generating article comprises a substantially planar upper surface and a lower surface, when viewed in plan, the perimeter of one or both of the upper and lower surfaces may have a shape that defines a polygon, a quadrilateral (e.g., a rectangle or square), an oval, a circle, or a combination thereof.

[0084] The aerosol-generating article may consist entirely of the aerosol-forming substrate. Alternatively, the aerosol-forming substrate may be one component part of a plurality of component parts of the aerosol-generating article.

[0085] 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.

[0086] Preferably, the aerosol-forming substrate comprises or consists of a homogenised tobacco material, such as reconstituted tobacco material or cast leaf tobacco material.

[0087] 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.

[0088] The aerosol-forming substrate may comprise one or more aerosol formers. Suitable aerosol formers are well known in the art and include, but are not limited to, one or more aerosol formers 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 former to be or include glycerol.

[0089] The aerosol-forming substrate may comprise at least 1%, 2%, 5%, 10% or 15% by weight of aerosol-forming agent. The aerosol-forming substrate may comprise greater than 15% by weight of 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 aerosol-forming agent.

[0090] The aerosol-forming substrate may comprise less than or equal to 30% by weight of aerosol-former, less than or equal to 25% by weight of aerosol-former, or less than or equal to 20% by weight of aerosol-former. In other words, the aerosol-forming substrate may have an aerosol-former 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.

[0091] The aerosol-forming substrate 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.

[0092] The aerosol-forming substrate may comprise between 5% and 30% by weight of aerosol-former, between 5% and 25% by weight of aerosol-former or between 5% and 20% by weight of aerosol-former.

[0093] The aerosol-forming substrate 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.

[0094] The aerosol-forming substrate 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.

[0095] The aerosol-forming substrate may comprise at least 50% by weight of aerosol-former, at least 60% by weight of aerosol-former or at least 70% by weight of aerosol-former.

[0096] The aerosol-forming substrate may comprise less than or equal to 85 wt% aerosol-former, less than or equal to 80 wt% aerosol-former or less than or equal to 75 wt% aerosol-former.

[0097] The aerosol-forming substrate 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.

[0098] The aerosol-forming substrate 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.

[0099] The aerosol-forming substrate 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.

[0100] The aerosol-forming substrate may comprise nicotine.The aerosol-forming material may comprise natural nicotine, or synthetic nicotine, or a combination of natural and synthetic nicotine.

[0101] The aerosol-forming substrate 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 substrate 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.

[0102] 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), lemongrass (lemon balm), basil, cinnamon, lemon basil, chives, coriander, lavender, sage, tea, thyme, and caraway. The one or more flavoring agents may comprise tobacco materials.

[0103] In the final product state, the aerosol-forming substrate may have a moisture content of about 5% to 25%, preferably about 7% to 15%. For example, the aerosol-forming substrate may be a homogenised tobacco material having a moisture content of about 5% to 25%, preferably about 7% to 15% in the final product state.

[0104] The aerosol-forming substrate may comprise tobacco leaves; 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; 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.

[0105] "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.

[0106] 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.

[0107] Examples of oriental tobaccos are Turkish Oriental, Greek Oriental, Semi-Oriental tobaccos, but also fire-cured American White Burley, such as Perique and Rustica.

[0108] 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.

[0109] The aerosol-forming substrate may comprise cellulose fibers. For example, the aerosol-forming substrate 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.

[0110] The aerosol-forming matrix may comprise organic fibers, such as non-tobacco fibers or tobacco fibers. For example, the aerosol-forming matrix may comprise approximately 5% to 20%, preferably approximately 7% to 15%, tobacco fibers. 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 matrix may comprise approximately 10% to 30%, preferably approximately 15% to 25%, of non-tobacco organic fibers. For example, 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.

[0111] The aerosol-forming substrate may comprise a binder. For example, the aerosol-forming substrate may comprise from about 1% to 10%, preferably from about 1% to 5%, of a binder, such as any of the common gums or pectins used in the food and beverage (F&B) industry. Preferred binders may be natural pectins (such as 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.

[0112] The aerosol-forming base may comprise an organic vegetable glycerin agent. For example, the aerosol-forming base may comprise 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, nettles, plantain, turmeric, yarrow, and compounds of these.

[0113] The aerosol-forming substrate may comprise an organic plant extract. For example, the aerosol-forming substrate 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, C10H200, 2-isopropyl-5-methylcyclohexanol) and p-menthan-3-ol, which is any secondary alcohol such as a diastereoisomer of 5-methyl-2-(propan-2-yl)cyclohexan-1-ol, such as obtained from Chaerophyllum macrospermum, Mesosphaerum sidifolium or other related plant species.

[0114] The aerosol-forming substrate 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 such as palm oil, coconut oil and wood-based oil.

[0115] The aerosol-forming substrate preferably comprises an aerosol former, for example about 5% to 35%, preferably about 10% to 25% of an aerosol former. Suitable aerosol formers known in the art include: glycerol; monohydric alcohols such as menthol; polyhydric alcohols such as triethylene glycol; esters of polyhydric alcohols such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl esters of these.

[0116] According to the present disclosure, an aerosol-generating system may be provided, comprising an aerosol-generating article as described herein, and an aerosol-generating device. The aerosol-generating device may be configured to engage with the aerosol-generating article and generate an aerosol from the aerosol-generating article. The aerosol-generating device may include a heater configured to heat an aerosol-forming material of the aerosol-generating article.

[0117] As used herein, the term "aerosol-generating article" may refer to an article that is capable of generating or releasing an aerosol.

[0118] 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.

[0119] 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.

[0120] 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.

[0121] 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.

[0122] As used herein with reference to the present invention, the term "nicotine" is used to describe nicotine, nicotine base, or nicotine salts.

[0123] 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 component parts of an aerosol-generating article.

[0124] 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.

[0125] 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.

[0126] 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.

[0127] 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.

[0128] 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.

[0129] The invention is defined in the claims. However, a non-exhaustive list of non-limiting examples is provided below. Any one or more features of these examples may be combined with any one or more features of another example, embodiment or aspect described herein.

[0130] Ex1. An aerosol-generating article for use with an aerosol-generating device to generate an inhalable aerosol, the aerosol-generating article comprising:

[0131] a planar upper layer and a planar lower layer vertically spaced from each other by a separation height defined in the z-direction; and

[0132] an air inlet, an air outlet, and an air flow passage extending between the air inlet and the air outlet, the air flow passage being defined between the planar upper layer and the planar lower layer and having a width defined in the y-direction,

[0133] The width of the air flow passage is greater than 1 mm, and the separation height is less than 5 mm.

[0134] Ex2. An aerosol-generating article according to example Ex1, wherein the airflow passage has a passage height defined in the z-direction, and the passage height is equal to the separation height.

[0135] Ex3. An aerosol-generating article according to example Ex1 or Ex2, wherein the planar upper layer and the planar lower layer are parallel.

[0136] Ex4. An aerosol-generating article according to any preceding example, wherein the separation height is the maximum vertical distance between the planar upper layer and the planar lower layer.

[0137] Ex5. An aerosol-generating article according to any of the preceding examples, wherein the planar upper layer comprises an upper outer surface and the planar lower layer comprises a lower outer surface, the upper outer surface and the lower outer surface being vertically spaced apart by a surface-to-surface height, wherein the surface-to-surface height is less than 5 mm.

[0138] Ex6. An aerosol-generating article according to any preceding example, wherein the separation height is less than 4 mm, such as less than 3 mm, such as less than 2 mm, such as less than 1 mm.

[0139] Ex7. An aerosol-generating article according to any preceding example, wherein the separation height is greater than 0.1 mm, such as greater than 0.2 mm, such as greater than 0.5 mm.

[0140] Ex8. An aerosol-generating article according to any preceding example, wherein the width of the airflow passage is greater than 1.2 mm, such as greater than 1.5 mm, such as greater than 2 mm.

[0141] Ex9. An aerosol-generating article according to any preceding example, wherein the width of the airflow passage is less than 3 mm, such as less than 2.8 mm, such as less than 2.5 mm.

[0142] Ex10. An aerosol-generating article according to any of the preceding examples, wherein the airflow passage has a cross-sectional area defined in the y and z directions, wherein the cross-sectional area of ​​the airflow passage is greater than 0.1 square millimeters and less than 15 square millimeters, for example, greater than 1 square millimeter and less than 12.5 square millimeters.

[0143] Ex11. An aerosol-generating article according to any preceding example, wherein the airflow passage has a length defined in the x-direction, wherein the length is greater than 15 mm and less than 40 mm, for example greater than 20 mm and less than 30 mm, for example 26 mm.

[0144] Ex12. An aerosol-generating article according to example Ex11, wherein the width of the airflow passage is uniform along the length of the airflow passage.

[0145] Ex13. An aerosol-generating article according to any of the preceding examples, wherein the airflow passage has a volume greater than 1.5 cubic millimeters, less than 600 cubic millimeters, greater than 15 cubic millimeters and less than 40 cubic millimeters, greater than 20 and less than 30, less than 187.5 cubic millimeters, or less than 450 cubic millimeters.

[0146] Ex14. An aerosol-generating article according to any preceding example, wherein the aerosol-generating article has a resistance to draw (RTD) in the direction of the airflow path of less than 20 mm H2O, such as less than 10 mm H2O.

[0147] Ex15. An aerosol-generating article according to any of the preceding examples, wherein the separation height is no more than 5 times the width of the airflow path, for example no more than 4 times the width of the airflow path, for example no more than 3 times the width of the airflow path.

[0148] Ex 16. An aerosol-generating article according to any preceding example, wherein the width of the airflow passage is an average width of the airflow passage defined in the y-direction across the separation height.

[0149] Ex17. An aerosol-generating article according to any preceding example, wherein the width of the airflow path is uniform along the separation height, for example, the cross-section of the airflow path defined in the y, z directions is square or rectangular.

[0150] Ex18. An aerosol-generating article according to any of the preceding examples, wherein the aerosol-generating article has an article width defined in the y-direction, wherein the width of the airflow path is at least 0.1 times the article width, for example, at least 0.2 times the article width, for example, at least 0.3 times the article width.

[0151] Ex19. An aerosol-generating article according to any preceding example, wherein the airflow route is formed by a single airflow channel extending between the air inlet and the air outlet.

[0152] Ex20. An aerosol-generating article according to any preceding example, wherein a plurality of discrete airflow channels together form the airflow pathway, wherein each channel extends from a channel air inlet to a channel air outlet.

[0153] Ex21. An aerosol-generating article according to Example Ex20, wherein each of the channel air inlets together forms an air inlet of the aerosol-generating article, and each of the channel air outlets together forms an air outlet of the aerosol-generating article.

[0154] Ex22. An aerosol-generating article according to example Ex20 or Ex21, wherein each discrete airflow channel has a channel width, wherein the width of the airflow passage is the cumulative width of each of the channel widths.

[0155] Ex23. An aerosol-generating article according to any one of Examples Ex20 to Ex22, wherein each discrete airflow channel has a channel interior volume, wherein the volume of the airflow passage is the cumulative volume of each of the channel interior volumes.

[0156] Ex24. An aerosol-generating article according to any preceding example, wherein the planar upper layer, the planar lower layer, or both the planar upper layer and the planar lower layer comprise an aerosol-forming substrate.

[0157] Ex25. An aerosol-generating system comprising an aerosol-generating article according to any preceding claim, and an aerosol-generating device configured to engage with the aerosol-generating article and generate an aerosol from the aerosol-generating article.

[0158] Examples will now be further described with reference to the accompanying drawings, in which:

[0159] Figure 1a is a perspective side view of an aerosol-generating article according to a first embodiment of the present disclosure;

[0160] Figure 1b yes Figure 1a an alternative perspective side view of an aerosol-generating article;

[0161] Figure 2 is a schematic end view of an aerosol-generating article according to a second embodiment of the present disclosure;

[0162] Figure 3 yes Figure 2 a schematic side view of an aerosol-generating article;

[0163] Figure 4 yes Figure 2 A schematic plan view of an aerosol-generating article;

[0164] Figure 5 Shown as Figure 2 Schematic diagram of a corrugated element used in an aerosol-generating article;

[0165] Figure 6 shows a perspective view of an aerosol-generating article according to a third embodiment of the present disclosure;

[0166] Figure 7 Shown Figure 6 an exploded perspective view of an aerosol-generating article;

[0167] Figure 8 Shown Figure 6 Another exploded perspective view of an aerosol-generating article;

[0168] Figure 9 Shown Figure 6 A schematic transverse cross-sectional view of an aerosol-generating article;

[0169] Figure 10 Shown Figure 6 A schematic longitudinal cross-sectional view of an aerosol-generating article;

[0170] Figure 11 shows an exploded perspective view of an aerosol-generating article according to a fourth embodiment of the present disclosure;

[0171] Figure 12 Shown Figure 11 A schematic transverse cross-sectional view of an aerosol-generating article;

[0172] Figure 13 Shown Figure 11 Schematic side cross-sectional view of an aerosol-generating article.

[0173] Figure 1a and 1b A perspective side view of an aerosol-generating article 100 according to a first embodiment of the present disclosure is shown. The aerosol-generating article 100 has a planar upper layer 110 and a planar lower layer 120.

[0174] The aerosol-generating article 100 includes an aerosol-forming substrate (not shown). The aerosol-generating article 100 is suitable for use with an aerosol-generating device to generate an inhalable aerosol. In one embodiment, the aerosol-generating article 100 may consist essentially of the aerosol-forming substrate. In another embodiment, the aerosol-forming substrate may be one component part of the aerosol-generating article 100. The aerosol-forming substrate may be enclosed within the interior of the aerosol-generating article 100.

[0175] The aerosol-forming substrate may at least partially define the exterior of the aerosol-generating article 100; for example, one or both of the first planar layer 110 and the second planar layer 120 may comprise or consist of the aerosol-forming substrate.

[0176] A suitable aerosol-forming substrate may be homogenised tobacco.

[0177] The aerosol-generating article comprises a planar upper layer 110 extending in a first plane and a planar lower layer 120 extending in a second plane, the second plane being parallel to and spaced apart from the first plane. The planar upper layer and the planar lower layer are vertically spaced apart from each other by a separation height defined in the z-direction of less than 5 mm. In this example, the separation height is 3.2 mm.

[0178] The aerosol-generating article 100 includes an air inlet 240, an air outlet 260, and an air flow path extending between the air inlet and the air outlet. The air flow path is defined between a planar upper layer 110 and a planar lower layer 120. The air flow path has a width defined in the y-direction that is greater than 1 mm. In this example, the width of the air flow path is 2.5 mm and is uniform along the length of the air flow path. The air flow path has a path height defined in the z-direction, wherein the path height is equal to the separation height.

[0179] The planar upper layer 110 includes an upper outer surface, and the planar lower layer 120 includes a lower outer surface, the upper outer surface and the lower outer surface being vertically spaced apart by a surface-to-surface height. In this embodiment, the upper outer surface of the planar upper layer 110 is the upper outer surface of the aerosol-generating article 100, and the lower outer surface of the planar lower layer 120 is the lower outer surface of the aerosol-generating article 100, so the surface-to-surface height in this embodiment is equal to the height of the aerosol-generating article extending in the z-direction (which may also be referred to as the thickness).

[0180] The aerosol-generating article 100 has a length extending in the x-dimension of 40 mm, a width extending in the y-dimension of 15 mm, and a height extending in the z-dimension (which may also be referred to as a thickness) of 3.6 mm. The cross-sectional area of ​​the airflow passage is 8 square millimeters. The length of the airflow passage is equal to the length of the aerosol-generating article, so the volume of the airflow passage is 320 cubic millimeters.

[0181] An airflow path 230 is defined through the aerosol-generating article 100 between the planar upper layer 110 and the planar lower layer 120. The airflow path 230 extends between opposing first and second ends 201, 202 of the aerosol-generating article 100. The first end 201 may define the distal end of the aerosol-generating article 100, and the second end 202 may define the proximal end of the aerosol-generating article. The airflow path 230 extends between the air inlet 240 and the air outlet 260 and through the airflow passageway of the aerosol-generating article. The airflow path 230 may be directed toward the mouth of a user to allow the user to inhale aerosol generated by heating the aerosol-forming substrate of the aerosol-generating article 100.

[0182] like Figure 1a and 1b As shown in FIG, both the air inlet 240 and the air outlet 260 have rectangular cross-sections in the zy direction, and the air flow path has a corresponding cross-section ( Figure 1a and 1b ), and is formed by a single air flow channel extending between the air inlet 240 and the air outlet 260.

[0183] The aerosol-generating article 100 is configured to be used as part of an aerosol-generating system. The aerosol-generating system comprises an aerosol-generating device configured to engage with the aerosol-generating article 100 and generate an aerosol from the aerosol-generating article. The aerosol-generating device may comprise a heater for heating an aerosol-forming substrate within the aerosol-generating article.

[0184] Figure 2 、 3 4 show an end view, a side view, and a plan view, respectively, of an aerosol-generating article 300 according to a second embodiment of the present disclosure. The aerosol-generating article 300 includes a planar upper layer 310, a planar lower layer 320, and an intermediate or separating layer 340 disposed between the upper layer 310 and the lower layer 320. The planar upper layer 310 and the planar lower layer 320 are vertically spaced apart from each other by a separation height defined in the z-direction of less than 5 mm.

[0185] The planar upper layer 310 is formed from a paper sheet having a thickness of 300 microns. The planar lower layer 320 is formed from a paper sheet having a thickness of 300 microns. The middle layer 340 is a corrugated element formed from a corrugated aerosol-forming substrate sheet 345. A suitable aerosol-forming substrate can be homogenized tobacco. Thus, the middle layer 340 can be formed from a corrugated homogenized tobacco material sheet 345.

[0186] Figure 5 Shown is a corrugated aerosol-forming substrate sheet 345. The corrugations have an amplitude 346 of 3 millimetres, equal to the separation height, and a wavelength 347 of 3 millimetres. The aerosol-forming substrate sheet 345 forming the intermediate layer 340 has a thickness of 150 micrometres.

[0187] The intersections 351 , 352 between the upper layer 310 and the middle layer 340 and between the lower layer 320 and the middle layer 340 include an adhesive joining the respective layers.

[0188] The aerosol-generating article 300 has a length extending in the x-dimension of 40 mm, a width extending in the y-dimension of 15 mm, and a height (or thickness) extending in the z-dimension of 3.6 mm.

[0189] The corrugations of the middle layer 340 form a first set of longitudinally extending channels 361, defined by the upper layer 310 and the middle layer 340, and a second set of longitudinally extending channels 362, defined by the lower layer 320 and the middle layer 340. The first set of longitudinally extending channels 361 and the second set of longitudinally extending channels 362 extend across the length of the aerosol-forming substrate, between the proximal end 371 and the distal end 372 of the substrate 345. The longitudinally extending channels 361, 362 define an airflow path through the substrate 345. Thus, the airflow path traverses both sides of the aerosol-forming substrate sheet 345. The porosity of the aerosol-generating article along the airflow path is approximately 90%. This provides an extremely low resistance to draw (RTD) of less than 5 mmH2O. In fact, the RTD is close to zero. The airflow path is defined by the airflow passages. The plurality of longitudinally extending channels 361, 362 together form an airflow passage extending between an air inlet and an air outlet. Each longitudinally extending channel extends between a channel air inlet and a channel air outlet. Each of the channel air inlets together forms an air inlet of the aerosol-generating article, and each of the channel air outlets together forms an air outlet of the aerosol-generating article.

[0190] The width of the airflow passage is the cumulative width of each of the plurality of longitudinally extending passages 361 and 362. In this embodiment, the cumulative width of each of the plurality of longitudinally extending passages 361 and 362 is twice the total width of the intermediate layer 340 in the y-direction for each wavelength minus the thickness of the corrugated element. In this embodiment, the width of the airflow passage is 14.1 mm.

[0191] The cross-sectional area of ​​the airflow passage in the yz direction is the cumulative cross-sectional area of ​​all cross-sectional areas in the yz direction of the plurality of longitudinally extending channels 361, 362. In this example, the cross-sectional area of ​​the airflow passage is therefore the cross-sectional area of ​​the aerosol-generating article in the yz dimension minus the cross-sectional area of ​​the middle layer 340 in the yz dimension, minus the cross-sectional area of ​​the upper layer 310 and the lower layer 320 in the yz dimension, which is 43.65 square millimeters.

[0192] The aerosol-forming substrate 345 may be any suitable aerosol-forming substrate sheet material.

[0193] During use of the aerosol-generating article 300, the aerosol-forming substrate 345 is heated so that the aerosol-forming substrate 345 releases volatile compounds, which are then entrained in air drawn into the channels 361 , 362 via the distal end 372. The volatile compounds then cool and condense to form an aerosol, which can be drawn out of the channels 361 , 362 of the aerosol-generating article 300 via the proximal end 371.

[0194] Figure 6 An aerosol-generating article 400 according to a third embodiment of the present disclosure is shown. The aerosol-generating article 400 includes a planar upper layer 424 forming a first planar outer surface 421 and a planar lower layer 425 forming a second planar outer surface 422, the planar upper layer 424 and the planar lower layer 425 being vertically spaced apart from each other by a separation height defined in the z-direction. A frame 450 is positioned between the first planar outer layer 424 and the second planar outer layer 425. The second planar outer surface 422 is positioned parallel to the first planar outer surface 421.

[0195] Figure 7 and 8 Shown Figure 6 Exploded view of the aerosol-generating article 400 of FIG. The frame 450 defines and at least partially defines the cavity 430. Figure 7 The cavity 430 is shown in an empty state. Figure 8 The cavity 430 is shown filled with an aerosol-forming substrate 440 . Figure 9 and 10Respective transverse and longitudinal cross-sectional views of the aerosol-generating article 400 are shown when the cavity 430 is filled with the aerosol-forming substrate 440 .

[0196] Planar upper layer 424 and planar lower layer 425 are made of 35-micron-thick cigarette paper and are in physical contact with and bonded to frame 450. Planar upper layer 424 overlies the first end of cavity 430 and forms a first cavity end wall 431. Planar lower layer 425 overlies the second end of cavity 430 and forms a second cavity end wall 432, which is opposite first cavity end wall 431. In other words, frame 450, planar upper layer 424, and planar lower layer 425 collectively define cavity 430.

[0197] The frame 450 has a hollow rectangular parallelepiped shape and is made of cardboard. The frame 450 defines an orifice that extends through the height (also referred to as the thickness) of the frame 450, and the orifice at least partially forms the cavity 430 of the aerosol-generating article 400. The frame 450 includes a peripheral wall 451 that defines the cavity 430. The peripheral wall 451 includes a front wall 413 and a rear wall 414. In more detail, the peripheral wall 451 is defined by an inner transverse surface 452 of the frame 450 and an outer transverse surface 453 of the frame 450. The inner transverse surface 452 of the peripheral wall 451 at least partially defines the perimeter of the cavity 430. The outer transverse surface 453 of the peripheral wall 451 at least partially defines the perimeter of the aerosol-generating article 400. The peripheral wall 451 has a radial thickness measured between the inner transverse surface 452 of the frame 450 and the outer transverse surface 453 of the frame 450 of approximately 5 mm.

[0198] The air inlet 411 and the air outlet 412 are defined by and extend through the peripheral wall 451 of the frame 450. More specifically, the air inlet 411 extends through the front wall 413, and the air outlet 412 extends through the rear wall 414. The air inlet 411 and the air outlet 412 have an equivalent diameter of 5 mm. An air flow path extends through the cavity 430 between the air inlet 411 and the air outlet 412. Figures 8 to 10 As shown in FIG, an aerosol-forming substrate 440 is positioned within the cavity 430. The aerosol-forming substrate 440 comprises an aerosol-generating material in the form of tobacco cut filler and has an aerosol-forming agent content of 5 wt% on a dry weight basis. As shown, the aerosol-forming substrate 440 fills the entire volume of the cavity 430.

[0199] The aerosol-generating article 400 has a rectangular parallelepiped shape and has a height (or thickness) extending in the z dimension of 5 mm (as measured between the first planar outer surface 421 and the second planar outer surface 422), a width extending in the y dimension of 40 mm, and a length extending in the x dimension of 60 mm. The frame 450 has a height (or thickness) extending in the z dimension of 4.93 mm, which is equal to the separation height defining the vertical separation between the planar upper layer 424 and the planar lower layer 425. The frame has a width extending in the y dimension of 40 mm and a length extending in the x dimension of 60 mm. The cavity 430 has a height (or thickness) extending in the z dimension of 4.93 mm (which is equal to the separation height and the height of the airflow passage), a width extending in the y dimension of 39.93 mm, and a length extending in the x dimension of 52 mm.

[0200] In this embodiment, the width of the air inlet 411 and the width of the air outlet 412 are not equal to the width of the cavity 430. The width of the air flow path can be defined as the width of the cavity 430. Therefore, the width of the air flow path is 39.93 mm.

[0201] Figure 11 An aerosol-generating article 500 according to a fourth embodiment of the present disclosure is shown. Like features to the aerosol-generating article 400 are indicated by like reference numerals. The aerosol-generating article 500 differs from the aerosol-generating article 400 in that the aerosol-forming substrate is in the form of a sheet 540 of aerosol-generating material, in particular a sheet of corrugated homogenised tobacco material. Figure 12 and 13 Shown Figure 11 Corresponding transverse and side cross-sectional views of the aerosol-generating article 500.

[0202] The corrugated homogenised tobacco material sheet 540 comprises a plurality of parallel corrugations having a plurality of substantially parallel peaks 543 and valleys 544. Figure 12 As seen in FIG, a plurality of parallel ripples are defined by a ripple profile, which is sinusoidal. A plurality of parallel ripples have a ripple wavelength of approximately 4.6 millimeters. As shown by the peaks 543 and valleys 544 that coincide with the first cavity end wall 431 and the second cavity end wall 432, respectively, the ripple amplitude is roughly the same as the height (or thickness) of the cavity 430. The corrugated homogenized tobacco material sheet 540 has a thickness of 150 microns.

[0203] The plurality of parallel corrugations form a plurality of channels 545 between the sheet of aerosol-generating material 540 and the first chamber end wall 431, and a plurality of channels 546 between the sheet of aerosol-generating material 540 and the second chamber end wall 432. The plurality of channels 545, 546 extend in the longitudinal direction of the aerosol-generating article 500 and form at least a portion of an airflow passage extending between the air inlet 411 and the air outlet 412.

[0204] Each channel in the plurality of channels 545, 546 has a channel width. Since the width of the channel is not constant in the z-direction, the channel width can be considered as the average width of the channel in the z-direction.

[0205] The width of the airflow path is the cumulative width of each of the plurality of longitudinally extending channels 545, 546. In this embodiment, the width of the airflow path is the width of the cavity 430 minus the thickness of the aerosol-forming material 540 at each peak and valley. In other words, the width of the airflow path is the cumulative width of the space available for airflow through the cavity. In this example, the width of the airflow path is 37 mm.

[0206] The cross-sectional area of ​​the air flow passage in the yz direction is the cumulative cross-sectional area of ​​all cross-sectional areas of the plurality of longitudinally extending channels 545 , 546 in the yz direction.

[0207] During use of each of the aerosol-generating articles 400, 500, the aerosol-forming substrate 440, 540 is heated to cause the aerosol-forming substrate 440, 540 to release volatile compounds, which are then entrained in air drawn into the cavity 430 through the air inlet 411. The volatile compounds then cool and condense to form an aerosol, which can be drawn out of the aerosol-generating article 400, 500 through the air outlet 412.

[0208] For exemplary purposes applicable to any of the above embodiments, the composition of a suitable aerosol-forming substrate may be as follows. Percentages are given as weight percentages relative to the product in its final state. The aerosol-forming substrate may have a moisture content of about 5% to 25%, preferably about 7% to 15%, in the final product state. The aerosol-forming substrate may further comprise the following:

[0209] 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.

[0210] 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.

[0211] 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.

[0212] 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.

[0213] 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.

[0214] "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.

[0215] For illustrative purposes, the composition of yet another aerosol-forming substrate (which may also be suitable for use as an aerosol-forming substrate in any of the above embodiments) is described below. Percentages are given as weight percentages relative to the product in its final state. The aerosol-forming substrate may comprise:

[0216] 1. An aerosol former, such as glycerol; e.g. about 10% to 40%, preferably about 20% to 30%.

[0217] 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.

[0218] 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.

[0219] 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.

[0220] Alternatively, such an aerosol-forming substrate 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.

[0221] For the purposes of this specification and the appended claims, unless otherwise indicated, all numbers representing 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 be specifically listed or may not be listed herein. Therefore, in this article, the number "A" is understood to be 10% of "A" ± "A". In this article, the number "A" can be considered to be a numerical value within the general standard error of 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 be specifically listed or may not be listed herein. The terms "in which" and "wherein" are used synonymously in this specification.

Claims

1. An aerosol-generating article for use with an aerosol-generating device to generate an inhalable aerosol, the aerosol-generating article comprising: a planar upper layer and a planar lower layer vertically spaced from each other by a separation height defined in the z-direction; as well as an air inlet, an air outlet, and an air flow passage extending between the air inlet and the air outlet, the air flow passage being defined between the planar upper layer and the planar lower layer and having a width defined in the y-direction, The width of the air flow passage is greater than 1 mm, and the separation height is less than 5 mm. 2 . An aerosol-generating article according to claim 1 , wherein the airflow passage has a passage height defined in the z-direction, and the passage height is equal to the separation height.

3. An aerosol-generating article according to claim 1 or 2, wherein the separation height is less than 4 mm, such as less than 3 mm, such as less than 2 mm, such as less than 1 mm.

4. An aerosol-generating article according to any preceding claim, wherein the separation height is greater than 0.1 mm, such as greater than 0.2 mm, such as greater than 0.5 mm.

5. An aerosol-generating article according to any preceding claim, wherein the width of the airflow passage is greater than 1.2 mm, such as greater than 1.5 mm, such as greater than 2 mm.

6. An aerosol-generating article according to any preceding claim, wherein the width of the airflow passage is less than 3 mm, such as less than 2.8 mm, such as less than 2.5 mm.

7. An aerosol-generating article according to any preceding claim, wherein the airflow passage has a cross-sectional area defined in the y, z directions, wherein the cross-sectional area of ​​the airflow passage is greater than 0.1 square millimeters and less than 15 square millimeters, for example greater than 1 square millimeter and less than 12.5 square millimeters.

8. An aerosol-generating article according to any preceding claim, wherein the airflow passage has a length defined in the x-direction, wherein the length is greater than 15 mm and less than 40 mm, such as greater than 20 mm and less than 30 mm, such as 26 mm.

9. An aerosol-generating article according to any preceding claim, wherein the aerosol-generating article has a resistance to draw (RTD) in the direction of the airflow path of less than 20 mm H2O, such as less than 10 mm H2O.

10. An aerosol-generating article according to any preceding claim, wherein the width of the airflow passage is the average width of the airflow passage defined in the y-direction across the separation height.

11. An aerosol-generating article according to any preceding claim, wherein the width of the airflow passage is uniform along the separation height, for example the cross-section of the airflow passage defined in the y, z directions is square or rectangular.

12. An aerosol-generating article according to any preceding claim, wherein the aerosol-generating article has an article width defined in the y-direction, wherein the width of the airflow path is at least 0.1 times the article width, for example at least 0.2 times the article width, for example at least 0.3 times the article width.

13. An aerosol-generating article according to any preceding claim, wherein the airflow route is formed by a single airflow channel extending between the air inlet and the air outlet.

14. An aerosol-generating article according to any one of claims 1 to 12, wherein a plurality of discrete airflow channels together form the airflow passage, and wherein each discrete airflow channel has a channel width, wherein the width of the airflow passage is the cumulative width of each of the channel widths.

15. An aerosol-generating article according to any preceding claim, wherein the planar upper layer, the planar lower layer, or both the planar upper layer and the planar lower layer comprise an aerosol-forming substrate.

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