Improved aerosol-generating articles, devices and systems

Abstract

An aerosol-generating article (200, 500) for use with an aerosol-generating device (300, 600) to form an inhalable aerosol. An aerosol-generating article (200, 500) includes an aerosol-forming substrate (210, 510) having a base (212) defined by an x dimension and a y dimension and a height defined by a z dimension. A first portion (214) of the aerosol-forming substrate (210, 510) comprises a first aerosol-forming material and a second portion (216) of the aerosol-forming substrate (210, 510) comprises a second aerosol-forming material different from the first aerosol-forming material. The first aerosol-forming material occupies an inner portion of the base (212) and the second aerosol-forming material occupies a peripheral portion of the base (212) that at least partially surrounds the inner portion.

Description

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

[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 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 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-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.

[0006] According to the present disclosure, an aerosol-generating article for use with an aerosol-generating device to form an inhalable aerosol is provided. The aerosol-generating article may include an aerosol-forming substrate. The aerosol-forming substrate may have a base. The base may be defined by an x-dimension and a y-dimension. The aerosol-forming substrate may have a height. The height may be defined by a z-dimension.

[0007] Thus, according to a first aspect of the present disclosure, there is provided an aerosol-generating article for use with an aerosol-generating device to form an inhalable aerosol. The aerosol-generating article comprises an aerosol-forming substrate having a base defined by an x-dimension and a y-dimension. The aerosol-forming substrate has a height defined by a z-dimension.

[0008] The x, y and z dimensions may extend in the x, y and z directions respectively. The x, y and z directions may all be perpendicular to each other.

[0009] In some embodiments, the magnitude of the x dimension may be between 80% and 120% or between 90% and 110% of the magnitude of the y dimension. Optionally, the x dimension is approximately the same magnitude as the y dimension.

[0010] Optionally, the base is substantially planar. The base may define the lower surface of the substrate or be referred to as the lower surface of the substrate. The base may define a substantially planar lower surface of the aerosol-forming substrate. Advantageously, a planar base or planar lower surface may allow for better thermal contact with a planar heater of the aerosol-generating device.

[0011] Optionally, one or both of the aerosol-forming substrate and the aerosol-generating article is in the form of a 3-dimensional shape that can be described as a sheet, a coin, a disk or a cylinder (for example a right cylinder or a right circular cylinder).

[0012] Optionally, one or both of the x-dimension and the y-dimension has a magnitude equal to or greater than 3 times the z-dimension. Optionally, one or both of the x-dimension and the y-dimension has a magnitude equal to or greater than 3.5 times the z-dimension. Optionally, one or both of the x-dimension and the y-dimension has a magnitude equal to or greater than 4 times the z-dimension. For example, one or both of the x-dimension and the y-dimension may have a magnitude equal to or greater than 4.5 times the z-dimension, or 5 times the z-dimension, or 5.5 times the z-dimension, or 6 times the z-dimension.

[0013] 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, a smaller temperature difference may exist 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 of 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.

[0014] Optionally, aerosol forms the form of the cylinder (such as a straight cylinder or a straight circular cylinder) defined by the base and height. Optionally, the base is circular or substantially circular. Advantageously, the symmetry of the circular base can allow the substrate to be inserted into the corresponding circular cavity of the device with any orientation. This can make it less troublesome for the user to insert the substrate into the device. For highly relatively small (such as highly less than 20,10 or 8mm) substrates, this may be particularly important. As the technician will appreciate, in this context, the term orientation can be used to refer to the rotational orientation of substrate around the z direction. Preferably, the cylinder is a solid cylinder. That is to say, preferably, the cylinder is not a hollow cylinder or a pipe, and the substrate is the form of the solid disk (such as aerosol forms the solid cylinder or the disk of substrate) of material.

[0015] In the case that base is circular or substantially circular, base can have diameter.Diameter can equal x dimension and y dimension.Diameter can have the magnitude that is equal to or greater than 3 times of z dimension or height.Diameter can have the magnitude that is equal to or greater than 3.5 times of z dimension or height.Diameter can have the magnitude that is equal to or greater than 4 times of z dimension or height, and described magnitude is for example greater than 5 times of z dimension or height, or greater than 5.5 times of z dimension or height, or greater than 6 times of z dimension or height.In the case that matrix is ​​right circular cylinder in shape, when the magnitude of diameter equals the height of matrix or 4 times of z dimension, the area of ​​base equals the area of ​​curved surface.Therefore, for the diameter greater than 4 times of height, the area of ​​base is greater than the area of ​​curved surface, and therefore (for example using flat heater) heating base may be more effective than attempt heating curved surface.

[0016] Optionally, the base is defined by a base 2-dimensional shape. This 2-dimensional shape may form the lower surface of the aerosol-forming substrate. Optionally, the aerosol-forming substrate comprises an upper surface. Optionally, the upper surface of the aerosol-forming substrate is defined by an upper surface 2-dimensional shape which may be identical in shape to the base 2-dimensional shape. The upper surface may be spaced apart from the base by a height. The upper surface may face in a direction opposite to the base. Both the base (which may also be referred to as the lower surface) and the upper surface may be planar surfaces, which are optionally located on parallel planes spaced apart by a height. Optionally, the aerosol-forming substrate has one or both of a substantially circular lower surface and a substantially circular upper surface.

[0017] Optionally, the base or lower surface is defined by a first 2-dimensional shape having a base perimeter. Optionally, the upper surface is defined by a second 2-dimensional shape having an upper surface perimeter. One or more perimeter surfaces may extend between the lower surface and the upper surface, optionally extending perpendicularly. One or more perimeter surfaces may be defined between the perimeter of the first 2-dimensional shape and the perimeter of the second 2-dimensional shape, optionally wherein the perimeter of the first shape is the same as the perimeter of the second shape.

[0018] Optionally, the aerosol-forming substrate has a substantially planar lower surface. Optionally, the aerosol-forming substrate has a substantially planar upper surface. Advantageously, a planar surface may allow for better thermal contact with a planar heater.

[0019] Optionally, the ratio of the largest of the x- and y-dimensions to the z-dimension is between 3:1 and 25:1, such as between 4:1 and 20:1, such as between 4.2:1 and 10:1, such as between 4.5:1 and 8:1. Where the base is circular or substantially circular, optionally, the ratio of the diameter of the base (e.g., as defined by the x- or y-dimension) to the z-dimension is between 4:1 and 20:1, such as between 4.2:1 and 10:1, such as between 4.5:1 and 8:1. Optionally, the ratio of the radius of the base (e.g., as defined by half the x- or y-dimension) to the z-dimension is between 2:1 and 10:1, such as between 2.1:1 and 5:1, such as between 2.25:1 and 4:1. Advantageously, these ratios may provide a compromise between at least the following four factors:

[0020] base surface area for heating, which can increase with x and y dimensions,

[0021] the temperature difference across the height of the substrate when heated at one or both of the base and the upper surface, which temperature difference may increase with the z dimension,

[0022] the structural stiffness of the substrate or article, which, for a substrate having x and y dimensions greater than 4 times the z dimension, may decrease with the x and y dimensions for a given z dimension and increase with the z dimension for given x and y dimensions, and

[0023] The substrate generates sufficient aerosol to satisfy the user's ability, which may increase with the x, y, and z dimensions.

[0024] Optionally, the aerosol-forming substrate has an upper surface and a lower surface as described above, and one or both of the upper surface and the lower surface are in the form of a circle or an oval or a polygonal 2-dimensional shape (for example a polygon selected from a triangle, square, rectangle, pentagon, hexagon, heptagon, octagon, nonagon and decagon).

[0025] Optionally, one or both of the x and y dimensions are between 10 mm and 50 mm, such as between 12 mm and 30 mm, such as between 14 mm and 26 mm, such as between 16 mm and 24 mm, such as between 18 mm and 22 mm, such as about 18 mm, or about 19 mm, or about 20 mm, or about 21 mm, or about 22 mm.

[0026] Optionally, the aerosol-forming substrate is in the form of a cylinder defined by a circular base and a height, and wherein the diameter of the base 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.

[0027] Optionally, the z dimension is between 1 mm and 5 mm, for example between 1.2 mm and 4.5 mm, for example between 1.4 mm and 4 mm, for example between 1.6 mm and 3.5 mm, for example between 1.7 mm and 3 mm, for example about 1.7 mm, or about 1.8 mm, or about 1.9 mm, or about 2 mm, or about 2.1 mm.

[0028] Preferably, the z dimension is less than 20 mm, such as less than 10 mm, such as less than 8 mm.

[0029] Optionally, the aerosol-forming substrate is in the form of a cylinder defined by a base and a height, and wherein the height is between 1 mm and 5 mm, for example between 1.2 mm and 4.5 mm, for example between 1.4 mm and 4 mm, for example between 1.6 mm and 3.5 mm, for example between 1.7 mm and 3 mm, for example about 1.7 mm, or about 1.8 mm, or about 1.9 mm, or about 2 mm, or about 2.1 mm.

[0030] It may be particularly preferred that the aerosol-forming substrate is in the form of a cylinder (e.g. a right circular cylinder) defined by a base and a height, wherein the diameter of the base is between 10 mm and 50 mm, preferably between 14 mm and 50 mm, and wherein the height is between 1 mm and 5 mm, preferably between 1 mm and 4 mm.

[0031] Advantageously, the dimensions discussed in the above paragraph may provide a compromise between the four factors discussed above with respect to the ratios between the x, y, and z dimensions.

[0032] Optionally, the article consists entirely of the aerosol-forming substrate.Advantageously, this may provide one or more of the following benefits: reduced cost of manufacturing the article, reduced article weight and hence reduced shipping costs of the article, and reduced waste from manufacturing or using the article.

[0033] Optionally, the aerosol-generating article comprises a porous layer. Optionally, the aerosol-generating article consists of an aerosol-forming substrate and a porous layer. The porous layer may cover at least one surface of the aerosol-forming substrate. Optionally, the porous layer completely encapsulates the aerosol-forming substrate. Optionally, the porous layer is a porous paper or a porous mesh. 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. The porous layer may have a total outer surface area. At least 20%, 50%, 80%, or 90% of the total outer surface area may be open, for example, to expose the substrate to the external environment, or to allow aerosols from the substrate to pass therethrough, or both. The porous layer may be or may include a mesh. The porous layer may be or include tea bag material. Advantageously, the porous layer may protect the aerosol-forming substrate from one or both of physical damage and chemical contamination. Advantageously, the porous layer may also help to prevent transfer of aerosol-forming material from the aerosol-forming substrate to a user holding the aerosol-forming substrate.

[0034] The aerosol-forming substrate may comprise an aerosol-forming material. Optionally, the aerosol-forming substrate consists entirely of an aerosol-forming material. Optionally, the aerosol-forming substrate comprises one or both of nicotine and tobacco. The aerosol-forming substrate may be substantially homogeneous. Optionally, the aerosol-forming substrate comprises or consists of a tobacco material, such as a homogenized tobacco material. Optionally, the aerosol-forming substrate comprises or consists of a solid aerosol-forming material. Optionally, the aerosol-forming substrate comprises or consists of a liquid aerosol-forming material held in a porous matrix. Optionally, the aerosol-forming substrate comprises or consists of a gel aerosol-forming material.

[0035] Optionally, the first portion of the aerosol-forming substrate comprises a first aerosol-forming material. Optionally, the second portion of the aerosol-forming substrate comprises a second aerosol-forming material. The second aerosol-forming material may be different from the first aerosol-forming material. Advantageously, a substrate having two different aerosol-forming materials may allow for combinations of aerosol-forming materials that may not otherwise be available. This may allow for, for example, the combination of flavorings to enhance the user experience.

[0036] Optionally, one or both of the first aerosol-forming material and the second aerosol-forming material comprises one or both of tobacco and nicotine. Optionally, one or both of the first aerosol-forming material and the second aerosol-forming material is substantially homogeneous. Optionally, one or both of the first aerosol-forming material and the second aerosol-forming material comprises or consists of a solid aerosol-forming material. Optionally, one or both of the first aerosol-forming material and the second aerosol-forming material comprises or consists of a liquid aerosol-forming material held in a porous matrix. Optionally, one or both of the first aerosol-forming material and the second aerosol-forming material comprises or consists of a gel aerosol-forming material.

[0037] Optionally, one or both of the first aerosol-forming material and the second aerosol-forming material extend through the height or z-dimension of the aerosol-forming substrate, for example through the entire height or z-dimension of the aerosol-forming substrate. Optionally, one or both of the first aerosol-forming material and the second aerosol-forming material extend through the entire height or z-dimension of the aerosol-forming substrate, from the base of the substrate to the upper surface of the substrate.

[0038] Optionally, the first portion or first aerosol-forming material occupies an inner portion of the base or substrate. Optionally, the second portion or second aerosol-forming material occupies a peripheral portion of the base or substrate. Optionally, the peripheral portion at least partially surrounds the inner portion. The inner portion may or may not include a radially central portion of the base. Thus, the first aerosol-forming material can be formed as a circular-based cylinder (e.g., a right circular cylinder) located at the radially central portion of the base or an annular cylinder (e.g., a right annular cylinder) positioned around the radially central portion of the base, and the second aerosol-forming material can be formed as an annular cylinder (e.g., a right annular cylinder) at least partially surrounding the first aerosol-forming material.

[0039] Optionally, the first portion or first aerosol-forming material occupies a radially inner or central portion of the base. Optionally, the second portion or second aerosol-forming material occupies a radially peripheral portion of the base that at least partially surrounds the inner or central portion. For example, optionally, the first aerosol-forming material is shaped as a circular-based cylinder located at the radially central portion of the base or as an annular cylinder positioned around the radially central portion of the base, and the second aerosol-forming material is shaped as an annular cylinder that at least partially surrounds the first aerosol-forming material.

[0040] Advantageously, the arrangement discussed in the two paragraphs above can mean that when the base of the substrate is placed in thermal contact with a planar heater having similarly an inner or central heating portion and an outer heating portion, the orientation of the substrate is unimportant. Regardless of the orientation, the first aerosol-forming material will be in thermal contact with the inner or central heating portion, and the second aerosol-forming material will be in thermal contact with the outer heating portion. This is not the case for a cylindrical substrate, for example, in which the first aerosol-forming material occupies the left half of the substrate and the second aerosol-forming material occupies the right half of the substrate. As will be understood by those skilled in the art, in this context, the term orientation can be used to refer to the rotational orientation of the substrate about the z-direction.

[0041] Thus, according to a particularly preferred embodiment of the first aspect of the present disclosure, there is provided an aerosol-generating article for use with an aerosol-generating device to form an inhalable aerosol. The aerosol-generating article comprises an aerosol-forming substrate having a base defined by an x-dimension and a y-dimension and a height defined by a z-dimension. 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 that is different from the first aerosol-forming material. The first aerosol-forming material occupies an interior portion of the base, and the second aerosol-forming material occupies a peripheral portion of the base that at least partially surrounds the interior portion. As will be understood by a skilled person after reading this disclosure, the features set forth herein may apply to one or both of the first aspect and this particularly preferred embodiment of the first aspect.

[0042] The first portion of the substrate may occupy a volume that is between 25% and 400%, 25% and 200%, 25% and 100%, or 25% and 50% of the volume of the second portion of the substrate. The total volume of the first aerosol-forming material of the substrate may occupy a volume that is between 25% and 400%, 25% and 200%, 25% and 100%, or 25% and 50% of the volume of the total volume of the second aerosol-forming material of the substrate.

[0043] Any one, both, or all of the aerosol-forming material, the first aerosol-forming material, and the second aerosol-forming material may comprise one or more organic materials, such as tobacco. Any one, both, or all of the aerosol-forming material, the first aerosol-forming material, and the second aerosol-forming material may comprise one or more of herb leaves, tobacco leaves, shredded tobacco ribs, reconstituted tobacco, homogenized tobacco, extruded tobacco, and expanded tobacco.

[0044] Any one, both, or all of the aerosol-forming material, the first aerosol-forming material, and the second aerosol-forming material may contain 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 is particularly preferred for the aerosol former to be or include glycerol.

[0045] Any one, both or all of the aerosol-forming material, the first aerosol-forming material and the second aerosol-forming material may comprise at least 1 wt%, 2 wt%, 5 wt%, 10 wt% or 15 wt% aerosol former.

[0046] Any one, both, or all of the aerosol-forming material, the first aerosol-forming material, and the second aerosol-forming material may comprise nicotine.

[0047] Any one, both, or all of the aerosol-forming material, the first aerosol-forming material, and the second aerosol-forming material 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 herbaceous plants, including but not limited to mint (such as peppermint and spearmint), lemon balm, basil, cinnamon, lemon basil, chives, cilantro, lavender, sage, tea, thyme, and caraway. The one or more flavoring agents may comprise tobacco materials.

[0048] Optionally, the aerosol-forming substrate includes an orifice. The orifice may extend through the entire height or z dimension of the substrate. The orifice may be located at a substantially central (e.g., radially central) portion of the substrate. Therefore, the orifice may be referred to as a radially central through hole. Advantageously, this orifice may help accommodate thermal expansion of the substrate during use. This may minimize deformation of the substrate, which may result in poor thermal contact with the planar heater if the substrate is deformed and thus bent or contracted away from the planar heater. Additionally, advantageously, the orifice may form an airflow path through the substrate. This may contribute to aerosol generation or aerosol entrainment into an airflow passing through or through the substrate.

[0049] The orifice may have a maximum cross-sectional dimension of at least 1, 2, 3, 5 or 10 mm, for example, a maximum dimension in the x or y direction. The orifice may have a maximum cross-sectional dimension of no more than 20 or 10 mm, for example, a maximum dimension in the x or y direction. The orifice may have a minimum cross-sectional dimension of at least 1, 2, 3, 5 or 10 mm, for example, a minimum dimension in the x or y direction. The orifice may have a minimum cross-sectional dimension of no more than 20 or 10 mm, for example, a minimum dimension in the x or y direction. Advantageously, these sizes can provide a compromise between adequately accommodating the thermal expansion of the substrate and the airflow through the substrate, and the substrate still contains enough aerosol-forming material to be able to form an aerosol sufficient to satisfy the user.

[0050] Optionally, the first aerosol-forming material is a first homogenised tobacco material. Optionally, the second aerosol-forming material is a second homogenised tobacco material having a different composition to the first homogenised tobacco material.

[0051] Optionally, the first homogenised tobacco material differs from the second tobacco composition by having at least one difference selected from: a different aerosol former content, a different tobacco content, a different flavourant content, a different water content and a different nicotine content.

[0052] Optionally, the plurality of holes or recesses are defined in the upper surface of the aerosol-forming substrate. Optionally, the plurality of holes or recesses are defined in the base or lower surface of the aerosol-forming substrate. Optionally, at least a portion of the plurality of holes are blind holes that do not extend through the entire height or z-dimension of the aerosol-forming substrate. Optionally, at least a portion of the plurality of holes are through holes that extend through the height or z-dimension of the aerosol-forming substrate (e.g., from the upper surface to the base).

[0053] Optionally, the aerosol-generating article is substantially symmetrical about a plane extending through a position midway between the base and the upper surface in the x and y dimensions. Optionally, the base and the upper surface of the aerosol-generating article are substantially indistinguishable. Optionally, the base and the upper surface of the aerosol-generating article are interchangeable, for example in the sense that substantially the same aerosol is released by heating the base of the substrate and by flipping the article upside down and heating the upper surface of the substrate (which can now be considered a new base). Optionally, both the base and the upper surface of the aerosol-generating article are equally suitable for being heated by a heater (e.g. a planar heater). Advantageously, this can allow a user to insert the article into the cavity of the aerosol-generating device without having to worry about the article being inverted.

[0054] The aerosol-forming substrate may be manufactured by any suitable process. For example, a slurry comprising the composition of the aerosol-forming material and additional water may be formed. The slurry may be cast and dried to form a sheet of the aerosol-forming material, which may then be cut into shapes.

[0055] A multi-material aerosol-forming substrate can be formed in a similar manner. For example, a first slurry can be formed comprising a first aerosol-forming material and additional water. A second slurry can be formed comprising a second aerosol-forming material and additional water. These first and second slurries can be cast and dried to form sheets of the first and second aerosol-forming materials.

[0056] The sheet of the first aerosol-forming material can then be cut and shaped into a long right circular cylinder. A sheet of the second aerosol-forming material can then be wrapped around the long right circular cylinder of the first aerosol-forming material to form a long right circular cylinder having a central portion of the first aerosol-forming material and an outer portion of the second aerosol-forming material. This long cylinder can then be cut at several locations across its curved surface. This can result in the formation of a plurality of aerosol-forming substrates that are short right circular cylinders in shape and have an inner central portion of the first aerosol-forming material and an outer peripheral portion of the second aerosol-forming material surrounding the first aerosol-forming material.

[0057] Alternatively, a short right circular cylinder can be punched out of a sheet of the first aerosol-forming material. A short right annular cylinder can be punched out of a sheet of the second aerosol-forming material. The short right circular cylinder of the first aerosol-forming material can then be placed into the center hole of the short right annular cylinder of the second aerosol-forming material. This can result in an aerosol-forming substrate that is a right circular cylinder in shape, having a height equal to the thickness of the sheets of the first and second aerosol-forming materials, and having an inner central portion of the first aerosol-forming material and an outer peripheral portion of the second aerosol-forming material surrounding the first aerosol-forming material.

[0058] As yet another alternative, aerosol-forming substrates can be manufactured using known extrusion processes. For example, a rigid slurry of an aerosol-forming material can be placed in an extruder and extruded through an extrusion head to form an elongated extrudate. This elongated extrudate is then preferably dried, for example by passing through a continuous drying oven, and sliced ​​to form individual aerosol-forming substrates. A dual-material aerosol-forming substrate can be formed in a similar manner using two extruders and a single dual extrusion head. Such systems are well known for the production of multi-material extrudates. For example, a first aerosol-forming material can be placed in a first extruder and fed through a first die of a dual extrusion head. Simultaneously, a second aerosol-forming material can be placed in a second extruder and fed through a second die of a dual extrusion head. The resulting extrusion can be in the form of a continuous cylinder having an inner portion of the first aerosol-forming material and an outer portion of the second aerosol-forming material. This continuous cylinder can then be dried and cut at multiple locations to form a plurality of aerosol-forming substrates according to the present disclosure, for example, aerosol-forming substrates according to preferred embodiments of the first aspect.

[0059] According to the present disclosure, an aerosol-generating device for heating an aerosol-generating article to form an aerosol is provided. The aerosol-generating device may include a cavity for receiving at least a portion (e.g., all) of the aerosol-generating article. The aerosol-generating device may include a heater for heating the aerosol-generating article, such as an aerosol-forming substrate of the aerosol-generating article. The heater may be arranged to provide heat to a base of the cavity. The base of the cavity may be sized to receive a base of an aerosol-generating article as described above, such as an aerosol-generating article according to the first aspect.

[0060] Thus, according to a second aspect of the present disclosure, there is provided an aerosol-generating device for heating an aerosol-generating article to form an aerosol. The aerosol-generating device comprises a cavity for receiving at least a portion (eg the entirety) of the aerosol-generating article, and a heater for heating the aerosol-generating article.

[0061] The heater is preferably arranged to provide heat to the base of the cavity.The base of the cavity is preferably dimensioned to receive the base of the aerosol-generating article according to the first aspect.

[0062] Advantageously, the heater is preferably arranged to provide heat to the base of the cavity, and the cavity is preferably sized to receive the base of the aerosol-generating article according to the first aspect. Thus, this can be a particularly effective heating means, particularly in cases where the base area of ​​the substrate is large (e.g., larger than the curved surface area).

[0063] Optionally, the heater is a planar heater. Optionally, the base of the cavity is substantially planar. Advantageously, a planar heater or base can provide good thermal contact with the planar surface of the aerosol-forming substrate.

[0064] The heater may be arranged at or below the base of the cavity.

[0065] Optionally, the heater includes a first portion and a second portion, wherein the first portion is configured to heat a first portion of the base of the cavity and the second portion is configured to heat a second portion of the base of the cavity. Optionally, the first portion of the heater is configured to heat an inner portion of the base of the cavity. The second portion of the heater can be configured to heat a peripheral portion of the base of the cavity. The peripheral portion can at least partially surround the inner portion of the base of the cavity. The inner portion can be a central portion of the base of the cavity or include the central portion of the base of the cavity. The inner portion can be substantially circular in cross-section or shape, or substantially annular in cross-section or shape. The peripheral portion can be substantially annular in cross-section or shape.

[0066] Optionally, the first portion of the heater is configured to heat a radially central portion of the base of the cavity. Optionally, the second portion of the heater is configured to heat a radially peripheral portion of the base of the cavity that at least partially surrounds the radially central portion of the base of the cavity, for example wherein the first portion of the heater is configured to heat a radially central circular portion of the base of the cavity and the second portion of the heater is configured to heat an annular portion of the base of the cavity surrounding the central portion of the base of the cavity.

[0067] Advantageously, the arrangement of the first and second parts of the heater discussed above may mean that, in use, the first and second parts of the heater contact the same portion of the aerosol-forming substrate, regardless of the orientation of the aerosol-forming substrate when inserted into the cavity of the device. As the skilled person will appreciate, in this context, the term orientation may be used to refer to the rotational orientation of the substrate about the z-direction.

[0068] Optionally, the first heater portion and the second heater portion are configured to operate independently of each other, for example to independently heat respective portions of the base of the chamber. Advantageously, this may allow the first heater portion and the second heater portion to heat the first and second portions of the aerosol-forming substrate to different temperatures, or to heat them at different times, or to different temperatures and at different times.

[0069] Optionally, the first and second heater portions are configured to operate simultaneously to heat respective portions of the base of the cavity. Advantageously, this may allow the first and second heater portions to heat the first and second portions of the aerosol-forming substrate simultaneously.

[0070] Optionally, the first heater portion and the second heater portion are configured to heat corresponding portions of the base of the cavity (e.g., the first portion and the second portion) to different temperatures. Advantageously, this may allow the first heater portion and the second heater portion to heat the first portion and the second portion of the aerosol-forming substrate to temperatures specifically optimized for the first portion and the second portion of the aerosol-forming substrate. For example, the first portion of the aerosol-forming substrate may release an optimized aerosol at a first temperature, but the second portion of the aerosol-forming substrate may be different from the first aerosol-forming substrate and may therefore release an optimized aerosol at a second temperature different from the first temperature. Therefore, in this case, the configuration of the first heater portion and the second heater portion to heat the first portion and the second portion of the base of the cavity to different temperatures may allow the release of an optimized aerosol from both the first portion and the second portion of the aerosol-forming substrate.

[0071] Optionally, the heater is or comprises a resistive heater.Optionally, one or both of the first heater portion and the second heater portion are or comprise a resistive heater.

[0072] Optionally, the heater is or comprises an induction heater. Optionally, one or both of the first heater portion and the second heater portion are or comprise an induction heater. The induction heater may comprise one or both of a susceptor and an inductor.

[0073] 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).

[0074] 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.

[0075] 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.

[0076] 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.

[0077] 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.

[0078] The aerosol generating device may comprise a second heater. The device body may comprise a second heater. The mouthpiece element may comprise a second heater.

[0079] The power supply may be configured to provide power to the second heater.The controller may control the power from the power supply to the second heater.

[0080] In the case where the mouthpiece element includes a second heater and the device body includes a power source, the mouthpiece element may be movable relative to the device body or connectable to the device body to electrically connect the power source of the device body to the second heater. For example, the device body may include a device body electrical contact connected to the power source, and the mouthpiece element may include a mouthpiece element electrical contact connected to the second heater. Furthermore, when the mouthpiece element is moved to a specific position relative to the device body or connected to the device body, the device body electrical contact may contact the mouthpiece element electrical contact to electrically connect the power source to the second heater.

[0081] The second heater may be configured to, in use, contact one or both of the upper and side surfaces of the aerosol-generating article or aerosol-forming substrate, or to provide heat thereto, or both.

[0082] The device (e.g. a mouthpiece element of the device or the device body) may comprise a second surface. The second surface may be a second heating surface. The second heater may comprise the second surface or be configured to provide heat to the second surface. The second surface may be configured to contact one or both of the upper and side surfaces of the aerosol-generating article or aerosol-forming substrate in use, or to provide heat thereto, or to both contact them and provide heat thereto. Thus, optionally, the device may be configured to provide heat to both the base and the second surface of the cavity. Advantageously, this may allow both the base and the upper or side surfaces of the aerosol-generating article or aerosol-forming substrate to be heated. This may allow a greater proportion of the substrate to be heated to a temperature at which the aerosol is released, whilst minimizing the risk of burning the hottest part of the substrate closest to the heater or the second heater. Alternatively or in addition, this may reduce the time required to sufficiently heat the substrate to release the aerosol.

[0083] The second surface may be configured to push the aerosol-generating article towards the base of the cavity during use. The aerosol-generating system may be configured such that when the article is at least partially (e.g., completely) received in the cavity of the device, the second surface of the device pushes or propels the article towards the base of the cavity of the device. Movement of the device from the second or disconnected position to the first or connected position may cause the second surface to contact the article or substrate, and optionally push against the article or substrate, for example, contact or push against the upper surface of the article or substrate. Advantageously, this pushing may help ensure good thermal contact between the base of the aerosol-forming substrate and the base of the cavity of the device. Additionally, where the second surface is heated during use, for example, by or because it is part of the second heater, this pushing may help ensure good thermal contact between the second heated surface and the upper surface of the aerosol-forming substrate.

[0084] In use, the second surface may provide a top wall of the cavity. Where the mouthpiece element comprises a second surface, the second surface may be configured to provide a top wall of the cavity when the mouthpiece is connected to the device body. Where the mouthpiece element comprises a second surface, the second surface may not provide a top wall of the cavity when the mouthpiece is not connected to the device body.

[0085] For example when the mouthpiece element is connected to the device body, the second heater or second surface may be located adjacent to or at least partially within a portion of the device body housing, optionally thereby providing a top wall of the cavity.

[0086] Where the mouthpiece element comprises a second surface or second heater, the mouthpiece element may be connectable to the device body so as to position the second surface or second heater adjacent to or at least partially within a portion of the device body housing, optionally thereby providing a top wall of the cavity.

[0087] One or both of the second surface and the second heater may be planar. Advantageously, the planar second heater or the planar second surface may provide good thermal contact with a planar surface of the substrate to be heated.

[0088] For example, when the mouthpiece element is attached to the device body, the second surface may be opposite the base of the cavity. For example, when the mouthpiece element is attached to the device body, the second heater may be opposite the heater. The planar surface of the second heater may be opposite the planar surface of the heater. The cavity may be located between the heater and the second heater, for example, between the planar surface of the heater and the planar surface of the second heater.

[0089] The spacing between the base and the second surface, for example the spacing between the planar surface of the base and the planar surface of the second surface, may be sufficient to accommodate the height or z-dimension of the aerosol-generating article. This spacing may be present when the mouthpiece element is connected to the device body. This spacing may be present when the device is in a first or connected position of the device (for example as opposed to a second or disconnected position of the device). This spacing may be at least 50%, 60%, 70%, 80% or 90% of the z-dimension of the aerosol-generating article before it is received in the cavity. This spacing may not exceed 200%, 150%, 120% or 110% of the z-dimension of the aerosol-generating article before it is received in the cavity. This spacing may be between 50% and 200%, preferably between 50% and 150%, and more preferably between 80% and 120% of the z-dimension of the aerosol-generating article before it is received in the cavity. As will be appreciated by the skilled person, the z-dimension of the article may be reduced when received in the cavity (for example if compressed between the base and the second surface). Advantageously, in use, the heater may heat the base of the article and the second heater may heat the upper surface of the article. Advantageously, this may allow a greater proportion of the substrate 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 or the second heater.

[0090] Features described with respect to the heater may apply to the second heater. In particular, features described with respect to the first heater portion and the second heater portion of the heater may apply to the first heater portion and the second heater portion of the second heater.

[0091] Thus, optionally, the second heater is a planar heater.Advantageously, a planar heater may provide good thermal contact with the planar surface of the aerosol-forming substrate.

[0092] The second heater may be arranged at, adjacent to, or below the second surface.

[0093] Optionally, the second heater includes a first portion and a second portion, wherein the first portion is configured to heat a first portion of the second surface and the second portion is configured to heat a second portion of the second surface. Optionally, the first portion of the second heater is configured to heat an inner portion of the second surface. The second portion of the second heater can be configured to heat a peripheral portion of the second surface. The peripheral portion can at least partially surround the inner portion. The inner portion can be a central portion of the second surface or include the central portion of the second surface. The inner portion can be substantially circular in cross-section or shape, or substantially annular in cross-section or shape. The peripheral portion can be substantially annular in cross-section or shape.

[0094] Optionally, the first portion of the second heater is configured to heat a radially central portion of the second surface. Optionally, the second portion of the heater is configured to heat a radially peripheral portion of the second surface at least partially surrounding the radially central portion of the second surface, for example wherein the first portion of the second heater is configured to heat a radially central circular portion of the second heated surface and the second portion of the second heater is configured to heat an annular portion of the second surface surrounding the central portion of the second surface.

[0095] Advantageously, the arrangement of the first and second parts of the second heater discussed above may mean that, in use, the first and second parts of the second heater heat the same portion of the upper surface of the aerosol-forming substrate, regardless of the orientation of the aerosol-forming substrate when inserted into the cavity of the device. As the skilled person will appreciate, in this context, the term orientation may be used to refer to the rotational orientation of the substrate about the z-direction.

[0096] Optionally, the first heater portion and the second heater portion of the second heater are configured to operate independently of each other, for example to independently heat respective portions of the base of the chamber. Advantageously, this may allow the first heater portion and the second heater portion of the second heater to heat the first and second portions of the aerosol-forming substrate to different temperatures, or at different times, or to different temperatures and at different times.

[0097] Optionally, the first heater portion and the second heater portion of the second heater are configured to operate simultaneously to heat respective portions of the second surface. Advantageously, this may allow the first heater portion and the second heater portion of the second heater to heat the first portion and the second portion of the aerosol-forming substrate simultaneously.

[0098] Optionally, the first heater portion and the second heater portion of the second heater are configured to heat corresponding portions of the second surface (e.g., the first portion and the second portion) to different temperatures. Advantageously, this may allow the first heater portion and the second heater portion of the second heater to heat the first portion and the second portion of the aerosol-forming substrate to temperatures specifically optimized for the first portion and the second portion of the aerosol-forming substrate. For example, the first portion of the aerosol-forming substrate may release an optimized aerosol at a first temperature, but the second portion of the aerosol-forming substrate may be different from the first aerosol-forming substrate and may therefore release an optimized aerosol at a second temperature that is different from the first temperature. Therefore, in this case, configuring the first heater portion and the second heater portion of the second heater to heat the first portion and the second portion of the second surface to different temperatures may allow optimized aerosols to be released from both the first portion and the second portion of the aerosol-forming substrate.

[0099] Optionally, the second heater is or comprises a resistive heater.Optionally, one or both of the first heater portion and the second heater portion of the second heater is or comprises a resistive heater.

[0100] Optionally, the second heater is or includes an induction heater. Optionally, one or both of the first heater portion and the second heater portion of the second heater are or include an induction heater. The induction heater may include one or both of a susceptor and an inductor.

[0101] The device (e.g., the device body) may include one or more peripheral walls surrounding the cavity. These one or more peripheral walls may extend from the base. For example, when the mouthpiece element is connected to the device body, these one or more peripheral walls may extend from the base at least partially to the second surface.

[0102] The device may comprise a third heater. The device body may comprise the third heater. The mouthpiece element may comprise the third heater. The third heater may comprise one or more peripheral walls surrounding the cavity or be configured to provide heat to one or more peripheral walls surrounding the cavity. Advantageously, the third heater may allow heating of the side surface between the base and the upper surface of the aerosol-generating article.

[0103] Optionally, the third heater is or includes a resistive heater. Optionally, the third heater is or includes an induction heater. The induction heater may include one or both of a susceptor and an inductor.

[0104] For example, when the mouthpiece element is connected to the device body, the second heater or second surface may be positioned adjacent to or at least partially within one or more peripheral walls surrounding the cavity, optionally thereby providing a ceiling of the cavity. Where the mouthpiece element comprises a second surface or second heater, the mouthpiece element may be connectable to the device body so as to position the second surface or second heater adjacent to or at least partially within one or more peripheral walls surrounding the cavity, optionally thereby providing a ceiling of the cavity.

[0105] 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.

[0106] According to the present disclosure, an aerosol-generating system is provided. The system may include an aerosol-generating article, for example, an aerosol-generating article as described above, such as an aerosol-generating article according to the first aspect. The system may include an aerosol-generating device, for example, an aerosol-generating device as described above, such as an aerosol-generating device according to the second aspect.

[0107] Thus, according to a third aspect of the present disclosure, there is provided an aerosol-generating system comprising an aerosol-generating article according to the first aspect and an aerosol-generating device according to the second aspect.

[0108] As set out above, the aerosol generating device may comprise a device body and a mouthpiece element, and the device body and mouthpiece element may be movable relative to each other, e.g. releasably connected. Thus, the device body and mouthpiece element may have a first or connected position and a second or disconnected position.

[0109] As used herein, the term "aerosol-generating article" may refer to an article that is capable of generating or releasing an aerosol.

[0110] 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.

[0111] 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.

[0112] 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.

[0113] 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.

[0114] Ex 1. An aerosol-generating article for use with an aerosol-generating device to form an inhalable aerosol, the aerosol-generating article comprising an aerosol-forming substrate having a base defined by x and y dimensions and a height defined by a z dimension.

[0115] Ex2. An aerosol-generating article according to example Ex1, wherein the x dimension is approximately the same magnitude as the y dimension.

[0116] Ex3. An aerosol-generating article according to any preceding example, wherein the base is substantially planar, for example wherein the base defines a substantially planar lower surface of the aerosol-forming substrate.

[0117] Ex4. An aerosol-generating article according to any preceding example, wherein one or both of the aerosol-forming substrate and the aerosol-generating article are in the form of a 3-dimensional shape that can be described as a sheet, a coin, a disk, or a cylinder (e.g., a right cylinder or a right circular cylinder).

[0118] Ex5. An aerosol-generating article according to any preceding example, wherein the aerosol-forming substrate comprises an aerosol-forming material.

[0119] Ex6. An aerosol-generating article according to any preceding example, wherein one or both of the x dimension and the y dimension has a magnitude equal to or greater than 4 times the z dimension, optionally equal to or greater than 6 times the z dimension.

[0120] Ex7. An aerosol-generating article according to any of the preceding examples, wherein the aerosol-forming substrate is in the form of a cylinder (e.g., a circular cylinder or a right cylinder or a right circular cylinder) defined by a base and a height, or wherein the aerosol-forming substrate is in the form of a rectangular parallelepiped defined by a base and a height.

[0121] Ex8. An aerosol-generating article according to any of the preceding examples, wherein the base is defined by a 2-dimensional shape forming a lower surface of the aerosol-forming substrate, and the upper surface of the aerosol-forming substrate is defined by a substantially identical 2-dimensional 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.

[0122] Ex9. An aerosol-generating article according to any of the foregoing examples, wherein the base of the aerosol-forming substrate forms a lower surface defined by a first 2-dimensional shape having a perimeter, and the aerosol-forming substrate further comprises an upper surface defined by a second 2-dimensional shape having a perimeter, and one or more peripheral surfaces extending between the first surface and the second surface, optionally extending vertically, for example, one or more peripheral surfaces defined between the perimeter of the first shape and the perimeter of the second shape, optionally wherein the perimeter of the first shape is the same as the perimeter of the second shape.

[0123] Ex 10. An aerosol-generating article according to any preceding example, wherein the aerosol-forming substrate has a substantially planar lower surface.

[0124] Ex11. An aerosol-generating article according to any preceding example, wherein the aerosol-forming substrate has a substantially circular lower surface.

[0125] Ex 12. An aerosol-generating article according to any preceding example, wherein the aerosol-forming substrate has a substantially planar upper surface.

[0126] Ex 13. An aerosol-generating article according to any preceding example, wherein the aerosol-forming substrate has a substantially circular upper surface.

[0127] Ex14. An aerosol-generating article according to any of the preceding examples, wherein the aerosol-forming substrate is in the form of a cylinder (e.g., a circular cylinder or a right cylinder or a right circular cylinder) defined by a substantially circular base and a height, for example, wherein the x dimension and the y dimension are equal to the diameter of the circular base of the cylinder, and wherein the z dimension is equal to the height of the cylinder.

[0128] Ex15. An aerosol-generating article according to example Ex14, wherein the diameter of the base of the cylinder is equal to or greater than 4 times the height of the cylinder.

[0129] Ex16. An aerosol-generating article according to example Ex14, wherein the radius of the base of the cylinder is equal to or greater than 2 times the height of the cylinder.

[0130] Ex17. An aerosol-generating article according to any preceding example, wherein the ratio of the largest of the x dimension and the y dimension to the 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.

[0131] Ex18. An aerosol-generating article according to any of the preceding examples, wherein the base is circular or substantially circular, wherein the ratio of the diameter of the base (e.g., as defined by the x dimension or the y dimension) to the 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.

[0132] Ex19. An aerosol-generating article according to any of the preceding examples, wherein the base is circular or substantially circular, wherein the ratio of the radius of the base (e.g., as defined by half of the x dimension or half of the y dimension) to the z dimension is between 2:1 and 10:1, e.g., between 2.1:1 and 5:1, e.g., between 2.25:1 and 4:1.

[0133] Ex20. An aerosol-generating article according to any one of Examples Ex1 to Ex11, wherein the aerosol-forming substrate has an upper surface and a lower surface, and one or both of the upper surface and the lower surface are in the form of a circular or oval or polygonal 2-dimensional shape (for example, a polygon selected from a triangle, square, rectangle, pentagon, hexagon, heptagon, octagon, nonagon and decagon).

[0134] Ex21. An aerosol-generating article according to any of the preceding examples, wherein one or both of the x dimension and the y dimension 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.

[0135] Ex22. An aerosol-generating article according to any of the preceding examples, wherein the aerosol-forming substrate is in the form of a cylinder defined by a circular base and a height, and wherein the diameter of the base 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.

[0136] Ex23. An aerosol-generating article according to any of the preceding examples, wherein the aerosol-forming substrate is in the form of a cylinder defined by a circular base and a height, and wherein the radius of the base is between 5 mm and 25 mm, for example, between 6 mm and 15 mm, for example, between 7 mm and 13 mm, for example, between 8 mm and 12 mm, for example, between 9 mm and 11 mm, for example, about 9 mm, or about 10 mm, or about 11 mm.

[0137] Ex24. An aerosol-generating article according to any of the preceding examples, wherein the z dimension is between 1 mm and 5 mm, for example, between 1.2 mm and 4.5 mm, for example, between 1.4 mm and 4 mm, for example, between 1.6 mm and 3.5 mm, for example, between 1.7 mm and 3 mm, for example, about 1.7 mm, or about 1.8 mm, or about 1.9 mm, or about 2 mm, or about 2.1 mm.

[0138] Ex25. An aerosol-generating article according to any of the preceding examples, wherein the aerosol-forming substrate is in the form of a cylinder defined by a base and a height, and wherein the height is between 1 mm and 5 mm, for example, between 1.2 mm and 4.5 mm, for example, between 1.4 mm and 4 mm, for example, between 1.6 mm and 3.5 mm, for example, between 1.7 mm and 3 mm, for example, about 1.7 mm, or about 1.8 mm, or about 1.9 mm, or about 2 mm, or about 2.1 mm.

[0139] Ex26. An aerosol-generating article according to any preceding example, wherein the article is entirely composed of the aerosol-forming substrate.

[0140] Ex27. An aerosol-generating article according to example Ex26, wherein the aerosol-forming substrate is entirely composed of an aerosol-forming material.

[0141] Ex28. An aerosol-generating article according to any one of Examples Ex1 to Ex25, wherein the aerosol-generating article consists of the aerosol-forming substrate and a porous layer covering at least one surface of the aerosol-forming substrate.

[0142] Ex29. An aerosol-generating article according to example Ex28, wherein the porous layer completely encapsulates the aerosol-forming substrate.

[0143] Ex30. An aerosol-generating article according to example Ex28 or Ex29, wherein the porous layer is a porous paper or a porous mesh.

[0144] Ex31. An aerosol-generating article according to any preceding example, wherein the aerosol-forming substrate comprises nicotine.

[0145] Ex32. An aerosol-generating article according to any preceding example, wherein the aerosol-forming substrate comprises or consists of a homogenised tobacco material.

[0146] Ex33. An aerosol-generating article according to any preceding example, wherein the aerosol-forming substrate comprises or consists of a solid aerosol-forming material.

[0147] Ex34. An aerosol-generating article according to any preceding example, wherein the aerosol-forming substrate comprises or consists of a liquid aerosol-forming material held within a porous substrate.

[0148] Ex35. An aerosol-generating article according to any preceding example, wherein the aerosol-forming substrate comprises or consists of a gel aerosol-forming material.

[0149] Ex36. An aerosol-generating article according to any preceding example, wherein the first portion of the aerosol-forming substrate comprises a first aerosol-forming material, and the second portion of the aerosol-forming substrate comprises a second aerosol-forming material different from the first aerosol-forming material.

[0150] Ex37. An aerosol-generating article according to example Ex36, wherein one or both of the first aerosol-forming material and the second aerosol-forming material extend through the height or z dimension of the aerosol-forming substrate, for example through the entire height or z dimension of the aerosol-forming substrate.

[0151] Ex38. An aerosol-generating article according to example Ex37, wherein the first aerosol-forming material occupies an interior or central portion of the base, and the second aerosol-forming material occupies a peripheral portion of the base at least partially surrounding the interior or central portion.

[0152] Ex39. An aerosol-generating article according to example Ex37 or Ex38, wherein the first aerosol-forming material occupies a radial central portion of the base and the second aerosol-forming material occupies a radial peripheral portion of the base surrounding the radial central portion, for example, wherein the first aerosol-forming material is formed as a circular or annular cylinder located at the radial center position of the base, and the second aerosol-forming material is formed as an annular cylinder at least partially surrounding the first aerosol-forming material.

[0153] Ex40. An aerosol-forming article according to any one of examples Ex36 to Ex39, wherein the first aerosol-forming material is a first homogenized tobacco material, and the second aerosol-forming material is a second homogenized tobacco material having a different composition than the first homogenized tobacco material.

[0154] Ex41. An aerosol-forming article according to example Ex40, 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-former content, different tobacco content, different flavoring content, different water content, and different nicotine content.

[0155] Ex42. An aerosol-generating article according to any preceding example, wherein a plurality of holes or recesses are defined in the upper surface of the aerosol-forming substrate.

[0156] Ex43. An aerosol-generating article according to any of the preceding examples, wherein the base forms the lower surface of the aerosol-forming substrate, the upper surface of the aerosol-forming substrate is substantially parallel to the lower surface and spaced apart from the lower surface by the z dimension, wherein a plurality of holes or recesses are defined in the upper surface of the aerosol-forming substrate.

[0157] Ex44. An aerosol-generating article according to example Ex42 or Ex43, wherein at least a portion of the plurality of holes are blind holes that do not extend through the height of the aerosol-forming substrate or do not extend through the entire z dimension.

[0158] Ex45. An aerosol-generating article according to example Ex42, Ex43 or Ex44, wherein at least a portion of the plurality of holes are through-holes extending through the height of the aerosol-forming substrate between the upper surface and the base.

[0159] Ex46. An aerosol-generating device for heating an aerosol-generating article, such as an aerosol-generating article according to any preceding example, to form an aerosol, the aerosol-generating device comprising;

[0160] a cavity for receiving the aerosol-generating article; and

[0161] a heater for heating the aerosol-forming article, the heater preferably being arranged to provide heat to the base of the cavity, preferably wherein the cavity or the base of the cavity is dimensioned to receive the base of the aerosol-generating article.

[0162] Ex47. An aerosol generating device according to example Ex46, wherein the heater is a planar heater arranged at or below the base of the cavity.

[0163] Ex48. An aerosol generating device according to example Ex46 or Ex47, wherein the heater comprises a first heater portion configured to heat a first portion of the base of the cavity, and a second heater portion configured to heat a second portion of the base of the cavity.

[0164] Ex49. An aerosol generating device according to example Ex48, wherein the first heater portion of the heater is configured to heat an interior or central portion of the base of the cavity, and the second heater portion of the heater is configured to heat a peripheral portion of the base of the cavity that at least partially surrounds the interior or central portion of the base of the cavity.

[0165] Ex50. An aerosol generating device according to example Ex48 or Ex49, wherein the first heater portion is configured to heat a radial central portion of the base of the cavity, and the second heater portion is configured to heat a radial peripheral portion of the base of the cavity that at least partially surrounds the central portion of the base of the cavity, for example, wherein the first heater portion is configured to heat a radial central circular portion of the base of the cavity, and the second heater portion is configured to heat an annular portion of the base of the cavity that surrounds the central portion of the base of the cavity.

[0166] Ex51. An aerosol generating device according to any one of Examples Ex48 to Ex50, wherein the first heater portion and the second heater portion are configured to operate independently of each other, for example to independently heat respective portions of the base of the cavity.

[0167] Ex52. An aerosol generating device according to any one of Examples Ex48 to Ex51, wherein the first heater portion and the second heater portion are configured to operate simultaneously to heat respective portions of the base of the cavity.

[0168] Ex53. An aerosol generating device according to any one of Examples Ex48 to Ex52, wherein the first heater portion and the second heater portion are configured to heat respective portions of the base of the cavity to different temperatures.

[0169] Ex54. An aerosol generating device according to any one of Examples Ex46 to Ex53, wherein the heater is or comprises a resistive heater.

[0170] Ex55. An aerosol generating device according to any one of Examples Ex46 to Ex53, wherein the heater is or comprises an induction heater, for example wherein the heater comprises a susceptor and an inductor.

[0171] Ex56. An aerosol-generating device according to any one of Examples Ex46 to Ex55, wherein the device comprises a second surface, optionally wherein the second surface is a planar surface.

[0172] Ex57. An aerosol generating device according to example Ex56, wherein the second surface is configured to contact the upper surface of the aerosol generating article or the aerosol forming substrate when the aerosol forming substrate or at least a portion thereof is received in the cavity of the device, for example, wherein, in use, the second surface is configured to contact the upper surface of the aerosol generating article or the aerosol forming substrate when the aerosol forming substrate or at least a portion thereof is received in the cavity of the device, and press the aerosol generating article or the aerosol forming substrate toward the base of the cavity.

[0173] Ex58. An aerosol generating device according to any one of Examples Ex56 to Ex57, wherein the second surface is opposite to the base of the cavity in at least one configuration of the device, optionally wherein the second surface and the base of the cavity are in parallel planes in at least one configuration of the device.

[0174] Ex59. An aerosol-generating device according to any one of Examples Ex56 to Ex58, wherein the device comprises a second heater, optionally wherein the second heater comprises the second surface or is configured to provide heat to the second surface.

[0175] Ex60. An aerosol generating device according to example Ex59, wherein, when the aerosol generating article is received in the cavity, the heater is configured to heat the base of the aerosol-forming substrate of the aerosol generating article, and the second heater is configured to heat one or both of the upper surface and the side surface of the aerosol-forming substrate of the aerosol generating article.

[0176] Ex61. An aerosol-generating device according to any one of examples Ex46 to Ex60, wherein the device comprises a device body and a mouthpiece element, optionally wherein the mouthpiece element is releasably connected to the device body.

[0177] Ex62. An aerosol-generating device according to example Ex61, when dependent on any one of examples Ex56 to Ex60, wherein the mouthpiece element comprises the second surface.

[0178] Ex63. An aerosol-generating system comprising an aerosol-generating article according to any one of Examples Ex1 to Ex45 and an aerosol-generating device according to any one of Examples Ex46 to Ex62.

[0179] Examples will now be further described with reference to the accompanying drawings, in which:

[0180] Figure 1 An aerosol-generating system is shown comprising an aerosol-generating article and an aerosol-generating device for use with the aerosol-generating article;

[0181] Figure 2 Shown in loaded connection position Figure 1 aerosol generating system;

[0182] Figure 3 A second aerosol-generating system is shown comprising a second aerosol-generating article and a second aerosol-generating device for use with the second aerosol-generating article; and

[0183] Figure 4 Yes Figure 1 A plan view of an aerosol-generating article is shown in FIG.

[0184] Figure 1 An aerosol-generating system 100 is shown comprising an aerosol-generating article 200 and an aerosol-generating device 300 for use with the aerosol-generating article 200 . Figure 2 The same system 100 is shown in a stowed connected position.

[0185] Aerosol generating article 200 Figure 4 2 and is for use with an aerosol-generating device 300 to form an inhalable aerosol. The aerosol-generating article 200 consists entirely of an aerosol-forming substrate 210 and is in the shape of a rounded right cylinder.

[0186] The substrate 210 has a planar circular base 212 and a planar circular upper surface 213, each having a diameter of approximately 20 mm, which may be referred to as the x-dimension or y-dimension of the substrate 210. The substrate 210 has a height extending from the base 212 to the upper surface 213 of approximately 3 mm, which may be referred to as the z-dimension of the substrate 210.

[0187] Aerosol forms substrate 210 and is made up of the first portion 214 of the first aerosol-forming material and the second portion 216 of the second aerosol-forming material that is different from the first aerosol-forming material. The first aerosol-forming material is the first homogenized tobacco material, and the second aerosol-forming material is the second homogenized tobacco material with a composition different from the first homogenized tobacco material. The first homogenized tobacco material is different from the second tobacco composition owing to having different flavoring agent contents. Specifically, the first homogenized tobacco material comprises the menthol flavoring that is evenly distributed throughout the material, and the second homogenized tobacco material does not comprise menthol flavoring. As will be understood by the technician, the first homogenized tobacco material can be for example different from the second tobacco composition in many aspects owing to having at least one difference that is selected from the following: different aerosol forming agent contents, different tobacco contents, different flavoring agent contents, different water contents and different nicotine contents.

[0188] For illustrative purposes, the composition of a suitable aerosol-forming material (which may be the second aerosol-forming material of the above-described specific embodiment) may be as follows. Percentages are given as weight percentages relative to the product in its final state. The second aerosol-forming material may be a second homogenized tobacco material having a moisture content of about 5 to 25%, preferably about 7 to 15%, in the final product state. Such a material may be used, for example, as the second portion 216 of the aerosol-forming substrate 210 described above. The second aerosol-forming material may also include the following:

[0189] 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.

[0190] 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.

[0191] 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.

[0192] 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.

[0193] 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.

[0194] "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.

[0195] 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.

[0196] Examples of oriental tobaccos are Turkish Oriental, Greek Oriental, Semi-Oriental tobaccos, but also fire-cured American White Burley, such as Perique and Rustica.

[0197] 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.

[0198] For illustrative purposes, another aerosol-forming material (which may be suitable as the first aerosol-forming material in the above-described specific embodiment) may have the following composition. Percentages are given as weight percentages relative to the product in its final state. The first aerosol-forming material may be used primarily for flavoring purposes and may be suitable as the first portion 214 of the aerosol-forming substrate 210 described above. The first aerosol-forming material may include:

[0199] 1. An aerosol former, such as glycerol; e.g. about 10 to 40%, preferably about 20 to 30%.

[0200] 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.

[0201] 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.

[0202] 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.

[0203] 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.

[0204] The aerosol-forming substrate can be formed from a first aerosol-forming material and a second aerosol-forming material using a known coaxial extrusion process. For example, the first aerosol-forming material can be placed in a first extruder and fed through a first central die of a dual extrusion head. Simultaneously, the second aerosol-forming material can be placed in a second extruder and fed through a second outer die of the dual extrusion head. The resulting extrusion can be in the form of a continuous cylinder having an inner portion of the first aerosol-forming material and an outer portion of the second aerosol-forming material. This continuous cylinder can then be dried, for example by passing through a continuous IR drying oven, and cut at multiple locations to form multiple aerosol-forming substrates having a central first portion 214 of the first aerosol-forming material and a radially outer second portion 216 of the second aerosol-forming material.

[0205] The first portion 214 and the second portion 216 extend through the entire height of the substrate 210. Figure 4As best seen in FIG, the first portion 214 is a right circular cylinder in shape and occupies a radially central portion of the matrix 210. The second portion 216 is an annular cylinder in shape and occupies a radially peripheral portion surrounding the central portion of the matrix 210. The outer diameter of the second portion 216 is approximately twice the outer diameter of the first portion 214.

[0206] The aerosol-forming substrate 210 comprises a plurality of recesses in its upper surface 213 ( Figure 1 The plurality of recesses do not extend through the entire height of the substrate 210. The aerosol-forming substrate 210 further comprises a plurality of through holes (not visible in FIG. 2 ) extending from the upper surface 213 through the entire height of the substrate 210 to the base 212 of the substrate 210. Figure 1 not visible in the ).

[0207] The aerosol generating device 300 comprises a mouthpiece element 310 and a device body 320 which are releasably connected to each other. As the skilled person will appreciate, such a releasable connection may be facilitated by any suitable means such as a magnetic connection, a snap-fit ​​connection or a threaded connection.

[0208] The device body 320 includes a device body housing 322 that defines a substantially right cylindrical cavity 324 for receiving the aerosol-generating article 200. The device body 320 also includes a power supply 326 and a controller 328. The device body 320 also includes a heater 330 that is configured to provide heat to a substantially circular, planar base 332 of the cavity 324.

[0209] The heater 330 is a planar heater disposed below the base 332 of the cavity 324. The heater 330 has a substantially circular cross-section and includes a first heater portion and a second heater portion. The first heater portion is a circular radially central portion of the heater 330, and the second heater portion is an annular radially peripheral portion of the heater 330 surrounding the first heater portion. The first heater portion is configured to heat the circular radially central portion of the base 332 of the cavity 324, and the second heater portion is configured to heat an annular radially peripheral portion of the base 332 of the cavity 324 surrounding the circular radially central portion of the base 332 of the cavity 324.

[0210] The first and second heater sections are configured to operate independently of each other. That is, the controller 328 is capable of independently controlling the power supply to the first and second heater sections. This allows the first and second sections of the base 332 of the cavity 324 to be heated independently. If desired, the first and second heater sections can be operated simultaneously to heat the first and second sections of the base 332 of the cavity 324.

[0211] The first heater portion and the second heater portion are configured to heat respective portions of the base 332 of the cavity 324 to different temperatures to heat the first portion 214 and the second portion 216 of the aerosol-forming substrate 210 to different temperatures. Specifically, the first heater portion is configured to heat the first portion of the base 332 of the cavity 324 to approximately 180 degrees Celsius, and the second heater portion is configured to heat the second portion of the base 332 of the cavity 324 to approximately 140 degrees Celsius. These two different temperatures are believed to release an optimal aerosol from the two different aerosol-forming materials of the first portion 214 and the second portion 216 of the substrate 210.

[0212] In this embodiment, heater 330 is a resistive heater. That is, heater 330 is a resistive heater. A first heater portion comprises a resistive track deposited on a circular substrate. A second heater portion comprises a resistive track deposited on an annular substrate surrounding the circular substrate. However, those skilled in the art will appreciate that the heater could also be an inductive heater, such as one comprising a susceptor and an inductor.

[0213] The mouthpiece element 310 includes an air inlet 312 and an air outlet 314. The air inlet 312 and the air outlet 314 are fluidly connected by an air flow path within the mouthpiece element 310.

[0214] In use, the aerosol-generating article 200 is received in the cavity 324 of the device body 320. The mouthpiece element 310 is then connected to the device body 320. This is considered the loading connection position of the aerosol-generating system 100. When the mouthpiece element 310 is connected to the device body 320, the second surface 316 of the mouthpiece element 310 contacts the upper surface 213 of the substrate 210 and presses against the upper surface of the substrate. This pressing pushes the substrate 210 towards the base 332 of the cavity 324, thereby ensuring good thermal contact between the base 212 of the substrate 210 and the base 332 of the cavity 324.

[0215] Figure 2 Shown in loaded connection position Figure 1 The aerosol generating system 100 is shown in FIG. 1 . The system 100 is ready for use in this position.

[0216] In use, a user can insert the proximal end of the mouthpiece element 310 including the air outlet 314 into their mouth. The user can then press a button (not shown) on the device body 320 and hold it pressed, and draw on the air outlet 314.

[0217] In response to pressing the button, the controller 328 supplies power from the power supply 326 to the heater 330. Specifically, the controller 328 supplies power from the power supply 326 to the first heater portion, and then also to the second heater portion after a short delay. This delay allows the first heater portion and the second heater portion to reach their optimal temperatures of 180 degrees Celsius and 140 degrees Celsius at approximately the same time. The device body 320 also includes a temperature sensor (not shown) for monitoring the temperature of the first heater portion and the second heater portion of the heater 330 when the button is pressed. Once the first heater portion and the second heater portion of the heater 330 are at their optimal temperatures, the controller 328 controls the power supply to the heater 330 based on feedback from the temperature sensor so that the heater portion is maintained at or near its optimal temperature.

[0218] Supplying power to the first and second heater portions causes the first and second heater portions to heat the first and second portions of the base 332 of the cavity 324 and, thus, the first and second portions 214 and 216 of the substrate 210 to release the first and second aerosols.

[0219] As the user draws on the air outlet 314, air is drawn in through the air inlet 312 of the mouthpiece element 310 and through the substrate 210. This airflow entrains the aerosol released from the substrate 210. The airflow and the entrained aerosol are then drawn through the air outlet 314 and delivered to the user. The airflow through the device 300 is determined by Figure 2 Indicated by the arrow in .

[0220] When the user finishes drawing air on the air outlet 314 , the user can release the button. Releasing the button causes the controller 328 to stop supplying power from the power source 326 to the heater 330 .

[0221] The user may repeat the puff or puffing process until satisfied or until they deem the article 200 to be exhausted. The user may then disconnect the mouthpiece element 310 from the device body 320 and discard the article 200. The device may then be reused with another aerosol-generating article.

[0222] Figure 3 A second aerosol-generating system 400 is shown, comprising a second aerosol-generating article 500 and a second aerosol-generating device 600 for use with the second aerosol-generating article 500. Figure 3 , the system 400 is in a loading connection position, similar to Figure 2 The system 100 shown in FIG.

[0223] Figure 3 500 products with Figure 1 and Figure 2 The following describes the same product 200. Figure 1 and Figure 2 The device 300 shown in FIG. Figure 3 The differences between the apparatus 600 shown in FIG.

[0224] The device 600 comprises a second heater 650. The mouthpiece element 610 comprises a second heater 650.

[0225] The mouthpiece element 610 is connectable to the device body 620 such that the power source 626 of the device body 620 is electrically connected to the second heater 650. Specifically, the device body 620 includes device body electrical contacts 625, 627 connected to the power source 626, and the mouthpiece element 610 includes mouthpiece element electrical contacts 615, 617 connected to the second heater 650. When the mouthpiece element 610 is connected to the device body 620, the device body electrical contacts 625, 627 contact the corresponding mouthpiece element electrical contacts 615, 617 to electrically connect the power source 626 to the second heater 650. Thus, the power source 626 is configured to provide power to the second heater 650. The controller 628 is configured to control the power from the power source 626 to the second heater 650.

[0226] The second heater 650 is secured to the second surface 616 and is configured to provide heat to the second surface. The second surface 616 is configured to, in use, contact the upper surface 513 of the aerosol-generating article 500, urge against the upper surface, and provide heat to the upper surface. The second surface 616 effectively provides a top wall for the cavity 624.

[0227] In this embodiment, the second heater 650 and the second surface 616 are similar in shape. They are both annular and have an outer diameter that is smaller than the outer diameter of the base 632 of the cavity 624 and the outer diameter of the substrate 510. This means that, in use, some aerosol, such as aerosol released from the first inner portion of the substrate 510, can pass through the central hole of the second heater 650 and the second surface 616, and some aerosol, such as aerosol released from the second outer portion of the substrate, can pass outside the outer diameter of the second heater 650 and the second surface 616.

[0228] Second heater 650 is similar to heater 630 in that it includes a first portion and a second portion configured to be heated to different temperatures and to heat the first and second portions of substrate 610. However, one difference is that the first portion of second heater 650 is annular in shape, while the first portion of heater 630 is circular in shape. Another difference is that second heater 650 is configured to provide heat to second surface 616 (which effectively provides a top wall of cavity 624 opposite to the base 632 of the cavity) and, therefore, heat upper surface 614 of substrate 610, while heater 630 is configured to provide heat to base 632 of cavity 624 and, therefore, heat base 512 of substrate 510.

[0229] Device body 620 also includes an inductor coil 660 and a susceptor 670. Susceptor 670 is in the form of a perforated annular peripheral wall extending from base 632 of cavity 624 and surrounding cavity 624. Inductor coil 660 and susceptor 670 form a third heater 680. Inductor coil 660 is wound around susceptor 670. As explained in more detail below, controller 628 controls the supply of power from power source 626 to inductor coil 660 to control the temperature of susceptor 670.

[0230] Similar to Figure 2 In the system 100 shown in FIG, in use, the user draws on the mouthpiece element 610 and presses a button (not shown) and holds it down. In response to the button being pressed, the controller 628 controls the supply of power from the power source 626 to the heater 630, the second heater 650, and the third heater 680.

[0231] Heater 630 and Figure 2 The heater 330 of the system 100 shown in FIG. 1 is identical and is controlled in the same manner.

[0232] The second heater 650 is also Figure 2 10. The second heater 650 is controlled in the same manner as the heater 330 of the system 100 shown in FIG. That is, the controller 628 supplies power from the power source 626 to the first portion of the second heater 650, and then, after a short delay, also to the second portion of the second heater 650. This delay allows the first and second portions of the second heater 650 to reach their optimal temperatures of 180 degrees Celsius and 140 degrees Celsius at approximately the same time. Once at their optimal temperatures, the controller 628 controls the power supply to the second heater 650 based on feedback from a second temperature sensor (not shown) in the mouthpiece element 610, so as to maintain the first and second portions of the second heater 650 at their optimal temperatures.

[0233] Regarding the third heater 680, when the button is pressed, the controller 628 sends an alternating current to the inductor coil 660. This causes the inductor coil 660 to generate a fluctuating electromagnetic field. This fluctuating electromagnetic field induces eddy currents in the susceptor 670, causing it to heat up. Thus, in use, the susceptor 670 heats the curved side surface of the substrate 510. Similar to the heaters 630 and the second heater 650, a third temperature sensor (not shown) is present that monitors the temperature of the third heater 680, specifically the susceptor 670 of the third heater 680, when the button is pressed. This third temperature sensor is located within the device body 620. Once the susceptor 670 reaches its optimal temperature, in this embodiment, 100 degrees Celsius, the controller 628 controls the power supply to the third heater 680, specifically the inductor coil 670 of the third heater 680, based on feedback from the third temperature sensor, to maintain the third heater 680, specifically the susceptor 670, at its optimal temperature.

[0234] In use, at least some of the aerosol released from the substrate 510 escapes through the perforations in the susceptor 670 which, as described above, is in the form of a perforated annular peripheral wall surrounding the cavity 624 extending from the base 632 of the cavity 624 .

[0235] Other details of the use of system 400 are as follows Figure 2 The use of the system 100 shown in FIG.

[0236] 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-generating article for use with an aerosol-generating device to form an inhalable aerosol, wherein: the aerosol-generating article comprising an aerosol-forming substrate having a base defined by an x-dimension and a y-dimension, and a height defined by a z-dimension, the ratio of the largest of the x-dimension and the y-dimension to the z-dimension being between 4:1 and 20:1; The first portion of the aerosol-forming substrate comprises a first aerosol-forming material and the second portion of the aerosol-forming substrate comprises a second aerosol-forming material different from the first aerosol-forming material; and The first aerosol-forming material occupies an interior portion of the base, and the second aerosol-forming material occupies a peripheral portion of the base at least partially surrounding the interior portion. 2 . An aerosol-generating article according to claim 1 , wherein the first portion is shaped as a circular or annular cylinder and the second portion is shaped as an annular cylinder.

3. An aerosol-generating article according to any preceding claim, wherein the first portion and the second portion extend across the entire height of the aerosol-forming substrate.

4. An aerosol-generating article according to any preceding claim, 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.

5. An aerosol-generating article according to any preceding claim, wherein the aerosol-forming substrate is shaped as a circular or annular cylinder and the outer diameter of the base of the aerosol-forming substrate is at least 4 times the height of the aerosol-forming substrate.

6. An aerosol-generating article according to any preceding claim, wherein the aerosol-forming substrate is in the form of a solid cylinder comprising the first aerosol-forming material and the second aerosol-forming material.

7. The aerosol-generating article of any preceding example, wherein one or both of the x-dimension and the y-dimension are between 10 mm and 50 mm.

8. An aerosol-generating article according to any preceding claim, wherein the z dimension is between 1 mm and 5 mm.

9. An aerosol-generating article according to any preceding claim, wherein the article consists entirely of the aerosol-forming substrate.

10. An aerosol-generating device for heating an aerosol-generating article according to any preceding claim to form an aerosol, the aerosol-generating device comprising; a cavity for receiving at least a portion of the aerosol-generating article, and a heater for heating the aerosol-forming article, the heater being configured to provide heat to a base of the cavity, The heater includes a first heater portion configured to heat an interior portion of the base of the cavity and a second heater portion configured to heat a peripheral portion of the base of the cavity at least partially surrounding the interior portion of the base of the cavity.

11. An aerosol generating device according to claim 10, wherein the first heater portion and the second heater portion are configured to operate independently of each other.

12. An aerosol generating device according to claim 10 or claim 11, wherein the first heater portion is configured to heat an interior portion of the base of the cavity to a first temperature, and the second heater portion is configured to heat a peripheral portion of the base of the cavity to a second temperature different from the first temperature.

13. An aerosol-generating device according to any one of claims 10 to 12, wherein the device comprises a second surface, and the second surface is configured to contact the aerosol-generating article or an upper surface of the aerosol-forming substrate when the aerosol-forming substrate is received in the cavity of the device.

14. An aerosol-generating device according to any one of claims 10 to 13, wherein the device comprises a second heater, different to the heater.

15. The aerosol generating device according to claim 14, wherein: When the aerosol-generating article is received in the cavity, the heater is configured to heat a base of an aerosol-forming substrate of the aerosol-generating article, and the second heater is configured to heat one or both of an upper surface and a side surface of the aerosol-forming substrate of the aerosol-generating article.

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