An aerosol-generating article comprising a roll of aerosol-forming substrate

Abstract

An aerosol-generating article for generating an aerosol. The aerosol-generating article comprises a roll of aerosol-forming substrate, the aerosol-forming substrate being defined by a length, a width and a thickness, wherein the length is greater in magnitude than the width, and the width is greater in magnitude than the thickness, wherein the thickness is greater than or equal to 0.5 millimetres, and wherein at least a portion of the aerosol-forming substrate is rolled along its length.

Description

Technical Field

[0001] This disclosure relates to an aerosol-generating article, an aerosol-generating system, and a method for manufacturing the aerosol-generating article. Background Technology

[0002] A typical aerosol generation system includes an aerosol generation device and an aerosol generation article. The aerosol generation device may include a heater, and the aerosol generation article may include an aerosol forming matrix. In use, the heater of the aerosol generation device heats the aerosol forming matrix of the aerosol generation article, causing volatile compounds to be released from the aerosol generation matrix. These compounds are then cooled to form an aerosol inhaled by the user.

[0003] Typical aerosol-generating articles can resemble conventional cigarettes. For example, such an aerosol-generating article can be a substantially cylindrical article comprising an aerosol-forming matrix and other components such as a mouthpiece filter element, all enclosed within cigarette paper. The dimensions of a typical aerosol-generating article are generally similar to those of a conventional cigarette. Typically, such aerosol-generating articles have a circular cross-section and extend between opposing first and second open ends. This type of aerosol-generating article typically includes a portion of an aerosol-forming matrix having a cylindrical shape corresponding to the circular cross-section of the article.

[0004] A typical aerosol-generating article is intended for a single-use process. For example, the aerosol-generating article is heated for a predetermined amount of time, or until another usage threshold is reached, and then heating can be stopped, ending the use process. The aerosol-generating article can be removed from the device and discarded. To begin a new use process, the user must insert another aerosol-generating article into the aerosol-generating device. This requires the user to carry the aerosol-generating device and at least one spare aerosol-generating article for insertion into the device. Carrying a spare aerosol-generating article and having to remove and insert it between each use process can be inconvenient for the user.

[0005] It is desirable to provide an aerosol-generating article suitable for use in multiple processes. Summary of the Invention

[0006] According to one aspect of this disclosure, an aerosol generating article for generating aerosols is provided. The aerosol generating article may include a roll of an aerosol forming matrix. The aerosol forming matrix may be defined by length, width, and thickness. The length may be greater than the width. The width may be greater than the thickness. The thickness may be greater than or equal to 0.5 mm. At least a portion of the aerosol forming matrix may be rolled up along its length.

[0007] Because the aerosol-forming matrix can be rolled up along its length, the aerosol-forming article can be conveniently used in more than one application. For example, a portion of the aerosol-forming matrix can be unrolled from the rolled-up portion, providing an unrolled portion of the aerosol-forming matrix. The unrolled portion can be heated for aerosol generation, while the rolled-up portion of the aerosol-forming matrix is ​​not heated. In this way, only a portion of the aerosol-forming matrix can be consumed during use. Therefore, the aerosol-forming article is suitable for use in multiple applications. Consequently, the user conveniently requires only one article for use in multiple applications, such as at least two, three, four, or five applications. For example, one article can be used in at least six, seven, eight, nine, or ten applications. Advantageously, the user does not need to carry multiple aerosol-forming articles. Therefore, this aerosol-forming article is more convenient for the user compared to typical single-use disposable aerosol-forming articles.

[0008] A width greater than thickness means the aerosol-forming matrix may not have a circular or square cross-section. The cross-section of the aerosol-forming matrix can be oval or rectangular. Compared to aerosol-generating articles with a circular cross-section, this aerosol-generating article can have a relatively high surface area to volume ratio. It is known that a circular cross-section of an aerosol-generating article may result in a relatively long time to reach a temperature sufficient to aerosolize the aerosol-forming matrix. This can lead to uneven heating of the aerosol-forming matrix.

[0009] Advantageously, the volume of the aerosol-forming matrix can be heated faster and more uniformly compared to an article with a circular cross-section. For example, if heated externally, the central portion of the aerosol-forming matrix may reach the desired temperature faster than an article with a circular cross-section. Consequently, heating across the aerosol-forming matrix may be more uniform, and therefore aerosol formation may be more uniform throughout the entire heated portion of the aerosol-forming matrix.

[0010] Compared to aerosol-generating articles with a circular cross-section, the amount of material in the aerosol-forming matrix can be reduced by decreasing the amount of outer paper and other non-aerosol-forming materials present in the aerosol-forming matrix, thereby potentially reducing costs and environmental impact.

[0011] The aerosol generating matrix can be flat. Advantageously, this allows for efficient heating of the aerosol generating matrix by a heating element and improves the yield of aerosols generated from the matrix. By having a large surface area to volume ratio and a thickness reduced compared to its length and width, the heating element can be positioned such that all aerosol generating matrix is ​​within a specified distance of the heating element. This offers the advantages of providing an improved user experience and reducing wasted aerosol generating matrix during use.

[0012] A thickness greater than or equal to 0.5 mm allows the aerosol-forming article to contain a sufficient amount of aerosol-forming matrix without being too wide or too long. This thickness advantageously contributes to the aerosol-forming article being robust enough for use in an aerosol-generating apparatus, while achieving uniform heating and aerosol generation. A thickness greater than or equal to 0.5 mm also results in improved airflow through the aerosol-forming matrix, for example, by providing a larger volume for airflow through, for example, via air channels or pores. Therefore, the aerosol-forming matrix can have lower suction resistance compared to a thinner aerosol-forming article, which allows for improved aerosolization. A thickness greater than or equal to 0.5 mm also allows for more complex structures within the aerosol-forming matrix, for example, it can allow the aerosol-forming matrix to include one or more layers in the thickness direction.

[0013] The aerosol generating article can be configured for use with an aerosol generating apparatus configured to heat an aerosol forming matrix. For example, the aerosol generating article can be configured to be inserted into or engaged with the aerosol generating apparatus.

[0014] Aerosol generating articles can be configured such that only a portion of the aerosol generating article is heated at a time. For example, the aerosol generating article can be partially deployed so that the deployed portion can be heated during use. Therefore, the aerosol generating article can be configured for use in multiple applications. Compared to common cylindrical or rod-shaped aerosol generating articles that are only for single use, this means that users do not need to frequently replace consumables. Aerosol generating articles configured for multiple uses are more convenient for users because they do not need to replace the aerosol generating article frequently.

[0015] The roll of aerosol forming material can be substantially cylindrical; for example, the roll of aerosol forming material can be wound in an Archimedean spiral. Alternatively, or additionally, the roll of aerosol forming material can have a height equal to the width of the aerosol forming matrix.

[0016] The thickness of the aerosol forming matrix can be greater than or equal to 0.6 mm, greater than or equal to 0.7 mm, greater than or equal to 0.8 mm, or greater than or equal to 0.9 mm, for example, greater than or equal to 1 mm or greater than or equal to 2 mm. Preferably, the thickness of the aerosol forming matrix can be equal to or greater than 1.5 mm.

[0017] The thickness of the aerosol forming matrix can be between 0.5 mm and 15 mm, for example, between 1.5 mm and 15 mm. The thickness of the aerosol forming matrix can be between 1 mm and 8 mm, for example, between 2 mm and 6 mm, for example, about 1.5 mm, or about 2 mm, or about 2.5 mm, or about 3 mm, or about 4 mm.

[0018] Advantageously, this thickness range offers a good trade-off between a thick enough aerosol forming matrix to contain a reasonable amount of aerosol forming matrix and to impart the advantages of an aerosol forming matrix with a thickness greater than 0.5 mm, but thin enough to allow the aerosol forming matrix furthest from the heater to be heated to a sufficiently high temperature to generate aerosols without the significant risk of the matrix closest to the heater burning.

[0019] The length of the aerosol-forming matrix in its unfolded state can be between 10 mm and 10,000 mm, for example between 20 mm and 800 mm, for example between 30 mm and 600 mm, for example between 150 mm and 500 mm. Advantageously, this length can be adapted to allow the use of aerosol-generated articles in multiple applications.

[0020] The length of the portion of the aerosol-forming matrix configured for use in a single application in its deployed state can be between 10 mm and 100 mm, for example between 20 mm and 80 mm, for example between 30 mm and 60 mm, for example about 30 mm, or about 35 mm, or about 40 mm, or about 50 mm. Advantageously, the length of the portion of the aerosol-forming matrix configured for use in its deployed state, compared to its length in a single application, means that the aerosol-forming matrix can be configured for use in at least three applications, for example at least five applications, for example at least seven applications, for example at least ten applications.

[0021] An aerosol-generating article can be configured such that, during use, a first portion is heatable by a heating element in a first use process. For example, in the first use process, the first portion of the aerosol-generating article is in contact with or adjacent to the heating element, such that the aerosol-forming matrix is ​​heatable by the heating element. For example, after the first portion has been heated and the first use process has ended, after a predetermined time or predetermined condition (e.g., a predetermined number of aspirations has been performed), the aerosol-generating article can be further unfolded so that the first portion of the aerosol-generating article is no longer within the range of the heating element that it is heatable by. A second portion of the heating element now contacts or is adjacent to the heating element, such that the aerosol-forming matrix is ​​heatable by the heating element, for example, in a second use process. In this way, subsequent portions of the aerosol-generating article are configured to be heatable to form an aerosol.

[0022] The width of the aerosol-forming matrix can be between 5 mm and 60 mm, for example between 10 mm and 50 mm, for example between 15 mm and 40 mm, for example about 15 mm, or about 20 mm, or about 25 mm, or about 30 mm. These widths, combined with length and thickness dimensions, can provide an aerosol-generating article that can be comfortably fitted into an aerosol-generating system whose size is comfortable for a user to maintain between their fingers, while also providing a sufficient amount of matrix to generate enough aerosol to satisfy the user during use.

[0023] The aerosol forming matrix can have a Young's modulus between 10 MPa and 1000 MPa, for example, between 30 MPa and 500 MPa. The Young's modulus of the aerosol forming matrix allows it to be rolled up along its length without breaking or being damaged.

[0024] The aerosol forming matrix may contain aerosol forming materials. The aerosol forming matrix may contain solid aerosol forming materials or be composed of solid aerosol forming materials. The aerosol forming matrix may contain liquid aerosol forming materials, such as liquid aerosol forming materials contained within a porous matrix. The aerosol forming matrix may contain gel aerosol forming materials.

[0025] Aerosol-forming materials may contain one or more organic materials, such as tobacco.

[0026] The aerosol forming matrix may contain tobacco-based materials, such as at least one of cast leaves or shredded fillers. Aerosol forming materials may include one or more of the following: herbaceous plant leaves, tobacco leaves, fragments of tobacco ribs, reconstituted tobacco, homogenized tobacco, extruded tobacco, and expanded tobacco.

[0027] The aerosol forming matrix may comprise a non-tobacco aerosol forming material, which includes an aerosol forming agent, such as glycerol or propylene glycol, and preferably includes flavor components and / or active components, such as nicotine. The aerosol forming matrix may comprise a humectant, such as at least one of propylene glycol, glycerin, or water.

[0028] Aerosol-forming materials may contain one or more aerosol-forming agents. Suitable aerosol-forming agents are those well known in the art and include, but are not limited to, one or more aerosol-forming agents selected from: polyols, such as propylene glycol, polyethylene glycol, triethylene glycol, 1,3-butanediol, and glycerol; esters of polyols, such as glycerol monoacetate, glycerol diacetate, or glycerol triacetate; and aliphatic esters of mono-, di-, or polycarboxylic acids, such as dimethyl dodecanoate and dimethyl tetradecanoate. Glycerol or aerosol-forming agents are particularly preferred.

[0029] The aerosol forming matrix may include at least one of paper or paperboard.

[0030] Aerosol-forming materials may include cellulose fibers. Aerosol-forming materials may include cotton.

[0031] Aerosol-forming materials may contain nicotine. Aerosol-forming materials may contain natural nicotine, synthetic nicotine, or a combination of natural and synthetic nicotine.

[0032] Aerosol-forming matrices may contain pharmacologically active ingredients.

[0033] The aerosol-forming material may contain one or more flavoring agents. The aerosol-forming matrix may contain at least one of menthol, L-carvone (spearmint), ethyl methyl phenyl glycidyl ester (strawberry), or peppermint oil.

[0034] One or more flavorings may contain 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 derived from herbs, including but not limited to peppermint (such as peppermint and spearmint), lemon balm, basil, cinnamon, lemon basil, chives, coriander, lavender, sage, tea, thyme, and fennel. One or more flavorings may contain tobacco materials.

[0035] Aerosol-forming materials may include a binder. For example, aerosol-forming materials may contain 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 pectin; guar gum, locust bean gum, and hydroxyethyl and / or hydroxypropyl derivatives of these; starch, such as modified or derivatized starch; alginate; methyl, ethyl, ethylhydroxymethyl, and carboxymethyl cellulose; dextran; and xanthan gum. Guar gum is a preferred binder.

[0036] The aerosol forming matrix may contain gelling agents, such as sodium alginate.

[0037] Aerosol-forming materials may contain organic plant-derived glycerol. For example, aerosol-forming materials may contain about 15% to 55%, preferably about 20% to 35%, of plant-derived materials such as clove, echinacea, fennel, ginger, hawthorn berries, elderberry fruit, horsemint, mullein leaves, nettle, plantain, turmeric, yarrow, and compounds thereof.

[0038] Aerosol-forming materials may contain organic plant-derived extracts. For example, aerosol-forming materials may contain about 1% to 15%, preferably about 2% to 7%, of any of the previously mentioned plant-derived materials, as well as menthol (dl-menthol, C10H20O, 2-isopropyl-5-methylcyclohexanol) and p-menthane-3-ol obtained from Chaerophyllum macrospermum, Mesosphaerum sidifolium or other related plant varieties, which are any secondary alcohols such as diastereomers of 5-methyl-2-(propyl-2-yl)cyclohexane-1-ol.

[0039] The aerosol forming material may contain plant-derived essential oils, such as about 0.5% to 5%, preferably about 1% to 3%, of plant-derived essential oils, such as palm oil, coconut oil and wood-based essential oils.

[0040] The aerosol-forming material preferably contains an aerosol-forming agent, for example, about 5% to 35%, preferably about 10% to 25%, of an aerosol-forming agent. Suitable aerosol-forming agents known in the art include: glycerol; monohydric alcohols, such as menthol; polyhydric alcohols, such as triethylene glycol; esters of polyhydric alcohols, such as mono-, di-, or triacetic acid esters; and aliphatic esters of mono-, di-, or polycarboxylic acids, such as dimethyl esters of these.

[0041] Aerosol forming materials may contain particles of functional materials, such as carbon, graphite, activated carbon, or expanded graphite. These materials can, for example, increase the thermal conductivity of the aerosol forming material and improve the efficiency of aerosol generation.

[0042] The aerosol forming matrix may also include a thermally conductive layer, such as an aluminum layer. The thermally conductive layer facilitates heat transfer between the heat source and the aerosol forming material of the aerosol forming matrix.

[0043] The aerosol forming matrix may also include a paper layer, such as a tipping paper layer, covering at least a portion of at least one surface of the aerosol forming matrix, for example, at least a portion of the upper surface or at least a portion of the lower surface.

[0044] The aerosol forming matrix may include conductive materials. For example, the aerosol forming material may include conductive particles. Conductive particles may be, for example, conductive carbon or graphite particles, or conductive metal particles, such as aluminum, stainless steel, or nickel particles.

[0045] The aerosol forming matrix may include one or more sensor materials. These sensor materials may be included within the aerosol forming material of the aerosol forming matrix, for example, as particles of sensor material distributed within the aerosol forming material. The presence of the sensor material allows the aerosol forming matrix to be heated by engaging with a fluctuating electromagnetic field generated by the sensor.

[0046] Optionally, one or more receptor materials may be included within the aerosol forming matrix as one or more receptor material strips, lines, or filaments, such as one or more receptor material strips, lines, or filaments located within the airflow path of the aerosol forming matrix.

[0047] Optionally, one or more receptor materials may be included within the aerosol forming matrix as one or more receptor material sheets or layers, such as covering the outer portion of the aerosol forming matrix or forming a structural component of the aerosol forming matrix.

[0048] One or more receptor material sheets can be in the form of a receptor material mesh.

[0049] The receptor material in any form may contain one or more materials selected from the following: aluminum, iron and iron alloys, nickel and nickel alloys, cobalt alloys, stainless steel alloys, copper alloys, carbon, expanded carbon, and graphite.

[0050] The aerosol forming matrix may include at least one of ferrous metals or ferrous metal alloys. The aerosol forming matrix may include metal foil.

[0051] An aerosol forming matrix may include two or more layers, such as two or more layers laminated together. For example, an aerosol forming matrix may include at least a first planar layer forming the upper surface of the aerosol forming matrix and a second planar layer forming the lower surface of the aerosol forming matrix.

[0052] Two or more layers may be bonded together by an adhesive (e.g., glue). Two or more layers may be bonded together by at least one of the following: PVA, gum arabic, PU, ​​epoxy resin, cyanoacrylate, polychloroprene, water-based adhesive, starch-based adhesive, cellulose-based adhesive, or natural rubber-based adhesive.

[0053] The aerosol forming matrix may include a first planar layer, a second planar layer, and an intermediate layer or separator layer disposed between the first planar layer and the second planar layer, wherein at least one of the first planar layer, the second planar layer, and the intermediate layer or separator layer comprises or is composed of an aerosol forming material.

[0054] At least one of the first planar layer, the second planar layer, and the intermediate layer or separation layer may include or be composed of an aerosol-forming material.

[0055] Preferably, the aerosol forming matrix includes corrugated portions, such as one or more corrugated elements, like a corrugated layer. For example, a corrugated layer is a sheet of corrugated material. The one or more corrugated elements preferably define a plurality of airflow channels extending through the aerosol forming matrix.

[0056] Ripples can be formed by many different ripple profiles. For example, ripples can also be defined by ripple profiles, which can be sinusoidal, triangular, rectangular, trapezoidal, circular, or parabolic.

[0057] The intermediate or separating layer may be a corrugated layer. For example, the aerosol forming matrix may include a first planar layer, a second planar layer, and a corrugated layer disposed between the first planar layer and the second planar layer, at least one of the first planar layer, the second planar layer, and the corrugated layer may include or be composed of an aerosol forming material.

[0058] The use of corrugated structures in aerosol-forming matrices advantageously allows for the production of aerosol-forming matrices with extremely low RTD while still maintaining sufficient rigidity for user handling. Furthermore, the use of corrugated structures allows for the production of low-density, low-RTD aerosol-forming matrices using high-speed production methods similar to those used for producing corrugated cardboard. The corrugated layers can increase the compressive strength of the aerosol-forming matrix.

[0059] The airflow path can be defined as passing through the matrix. The airflow path can be defined by at least one corrugated element. For example, the ridges and valleys of at least one corrugated element can be aligned substantially parallel to the airflow direction, thereby forming an airflow path in that direction.

[0060] The aerosol forming matrix comprises an aerosol forming material. Preferably, the aerosol forming material forms at least a portion of a corrugated structure or corrugated element. The aerosol forming material may be in the form of a sheet serving as one or more components of the corrugated structure or corrugated element. This allows for great flexibility in selecting different combinations of aerosol forming materials. This also allows for the selection of suitable non-aerosol forming materials for other purposes, such as to improve the structure of the matrix. In some instances, the entire aerosol forming matrix is ​​formed of an aerosol forming material.

[0061] The first planar layer can be the upper layer. The second planar layer can be the lower layer. An intermediate layer can be located between the upper and lower layers.

[0062] Preferably, the upper layer comprises or is formed of a planar material sheet, the lower layer comprises or is formed of a planar material sheet, and the middle layer comprises or is formed of a corrugated material sheet. In this case, at least some of the airflow channels in the corrugated airflow channels are at least partially defined by the aerosol-forming material. This allows aerosols generated by the aerosol-forming material to be easily entrained in the airflow path.

[0063] The corrugated layer includes corrugations that can be arranged perpendicular to the length direction of the aerosol-forming matrix in its unfolded state and parallel to the width direction of the aerosol-forming matrix. For example, the corrugations can be arranged perpendicular to the roll-up direction of the aerosol-forming matrix. The corrugations perpendicular to the roll-up direction advantageously provide weak roll-up resistance, thus allowing the aerosol-forming matrix to be easily rolled up and enabling the roll to have a desired radius of curvature.

[0064] The intermediate or separating layer can be a curled layer. The curled layer may include or consist of a curled tobacco layer.

[0065] The intermediate or separating layer may have a honeycomb structure. The honeycomb structure may include multiple pores passing through the layer. The arrangement of the pores can be omnidirectional. The honeycomb layer does not need to be arranged in any particular orientation relative to the roll-up direction of the aerosol-forming matrix.

[0066] The intermediate or separating layer may include or be composed of porous materials. Porous materials may inherently contain voids. Porous materials may be impregnated with aerosol-forming materials. For example, the voids may contain aerosol-forming materials.

[0067] The intermediate or separating layer comprises or is composed of fibrous materials. The fibrous materials may be impregnated with aerosol-forming materials.

[0068] The length of the aerosol-forming matrix in its deployed state can be defined by the x-dimensional dimension extending in the x-direction. The width of the aerosol-forming matrix in its deployed state can be defined by the y-dimensional dimension extending in the y-direction. The height or thickness of the aerosol-forming matrix in its deployed state can be defined by the z-dimensional dimension extending in the z-direction.

[0069] The aerosol-forming matrix, in its unfolded state, may include: a substantially planar upper surface defined by a length extending in the x-direction and a width extending in the y-direction; and a substantially planar lower surface defined by a length extending in the x-direction and a width extending in the y-direction. The substantially planar upper surface and the substantially planar lower surface may be vertically spaced apart from each other by a height defined in the z-direction. The height defined in the z-direction may be the thickness of the aerosol-forming matrix.

[0070] The airflow path can be defined as passing through the aerosol forming matrix. A low-resistance airflow path can be defined as passing through the aerosol forming matrix; for example, the aerosol forming matrix along the airflow path can have a suction resistance (RTD) of less than 80 mmH2O, or less than 40 mmH2O, or less than 30 mmH2O. An aerosol forming matrix with a low-resistance airflow path allows for excellent airflow management and allows aerosols to be extracted more efficiently from the aerosol forming matrix and guided to the user.

[0071] An airflow path can extend across the matrix from one side edge to the other along the y-axis; for example, an airflow path can extend substantially in the y-direction.

[0072] An airflow path can extend across the matrix from one end to the other along the x-axis; for example, an airflow path can extend substantially in the x-direction.

[0073] The airflow path through the aerosol-forming matrix can be defined by porosity (e.g., the percentage of the matrix free of aerosol-forming material). In this case, the porosity is open-pore porosity, thus allowing the airflow path through the matrix. Therefore, the aerosol-forming matrix can have an airflow path defined as passing through the aerosol-forming matrix from one side to the other in the x / y plane, and the aerosol-forming matrix can have a porosity greater than 60%, for example, greater than 80%, in the direction of the airflow path. The porosity can be greater than 60%, for example, greater than 80%, in at least one direction in the x / y plane of the aerosol-forming matrix. The aerosol-forming matrix can also have porosity greater than 60%, for example, greater than 80%, in a direction perpendicular to the z-direction. For example, the airflow path can be defined as passing through the aerosol-forming matrix along the x-direction from one side to the other, such that the aerosol-forming matrix has a porosity greater than 60%, for example, greater than 80%, in the x-direction. The aerosol forming matrix may have a gas flow path defined as passing through the aerosol forming matrix from one side to the other along the y-direction, such that the aerosol forming matrix has a porosity greater than 60%, for example, greater than 80%, in the y-direction. The porosity of the gas flow path may be defined by the ratio of the cross-sectional area of ​​the material within the gas flow path to the internal cross-sectional area of ​​the gas flow path.

[0074] Preferably, in the direction of the airflow path, the porosity is between 81% and 99%, for example, between 85% and 95%, for example, between 88% and 92%, for example, about 90%.

[0075] The radius of curvature of the aerosol forming matrix at the innermost part of the roll can be less than 4 times the thickness of the aerosol forming matrix, for example less than 3.5 times the thickness, or less than 3 times the thickness, or less than 2.5 times the thickness, or less than 2 times the thickness.

[0076] The radius of curvature of the aerosol forming matrix at the innermost part of the roll can be between 2 mm and 30 mm, for example between 2.5 mm and 20 mm, for example between 3 mm and 15 mm, for example between 4 mm and 8 mm.

[0077] Advantageously, the chosen radius of curvature means that the rolled-up aerosol-forming matrix can be rolled up in a compact manner and is therefore suitable for user carrying, and the aerosol-generated article is suitable for insertion into a handheld aerosol-generating device.

[0078] As used herein, the “radius of curvature” of an aerosol-forming matrix refers to the radius of the circle that is tangent to the curve of the aerosol-forming matrix at a given point on the curve. The radius of curvature of the aerosol-forming matrix can be measured on the surface of the aerosol-forming matrix facing the center of the circle.

[0079] The aerosol-forming matrix can be wound onto a spool. The aerosol-forming matrix can be wound onto a rotating shaft. The aerosol-forming matrix can be wound onto the shaft of the spool. The rotating shaft can be configured to act as a pivot for unwinding the aerosol-forming matrix as needed. The maximum thickness or diameter of the rotating shaft or shaft can be between 2 mm and 10 mm, for example, between 3 mm and 9 mm, or between 4 mm and 8 mm. These thicknesses allow the aerosol-forming matrix to be wound with a small radius of curvature.

[0080] The roll of the aerosol forming matrix can be located within a shell, for example, a substantially cylindrical shell. Advantageously, the shell can protect the aerosol forming matrix.

[0081] The shell may include a cap for retaining the rolled-up aerosol-forming matrix within the shell.

[0082] The aerosol-forming matrix can be wound onto a spool or shaft, which can be located in the substantially radially central portion of a shell (e.g., a cylindrical shell). The spool or shaft allows the aerosol-forming matrix to be unwound during use.

[0083] Aerosol-generating articles may include multiple perforations, such as sprocket holes, for tensioning the aerosol-forming matrix. For example, perforations or sprocket holes can facilitate winding, unwinding, or winding and unwinding of a roll of the aerosol-forming matrix. For example, perforations or sprocket holes can be arranged for engagement with a mechanical device, such as a sprocket. The mechanical device, such as a sprocket, can be disposed within an aerosol-generating apparatus.

[0084] Multiple perforations or sprocket holes can be arranged in a row extending in the x direction of the aerosol forming matrix, for example, in two rows extending in the x direction, with the two rows spaced apart in the y direction.

[0085] According to a second aspect of this disclosure, an aerosol generating article for generating aerosols can be provided. The aerosol generating article may include an aerosol forming matrix. The aerosol forming matrix may be defined by length, width, and thickness. The length may be greater than the width. The width may be greater than the thickness. The thickness may be greater than or equal to 0.5 mm. Preferably, the thickness may be greater than or equal to 1.5 mm.

[0086] The aerosol-generating articles of the second aspect may include any combination of features described with reference to any other aspect or example of this disclosure.

[0087] The length of the aerosol-forming matrix can be between 10 mm and 10,000 mm, for example between 20 mm and 800 mm, for example between 30 mm and 600 mm, for example between 150 mm and 500 mm. Advantageously, this length can be adapted to allow the use of aerosol-generated articles in multiple applications.

[0088] Preferably, the length is at least twice the width. More preferably, the length is at least three, four, or five times the width. For example, the length can be at least ten, fifteen, or twenty times the width.

[0089] Aerosol-forming articles are conveniently suited for use in more than one application process. For example, a portion of the aerosol-forming matrix can be heatable for aerosol generation, while the remaining aerosol-forming matrix is ​​not heated. In this way, only a portion of the aerosol-forming matrix can be consumed during use. Therefore, aerosol-forming articles are suitable for use in multiple applications. Consequently, users can conveniently require only one article for use in multiple applications, such as at least two, three, four, or five applications. For example, one article can be suitable for use in at least six, seven, eight, nine, or ten applications. Advantageously, users may not need to carry multiple aerosol-forming articles. Therefore, this aerosol-forming article may be more convenient for users compared to typical single-use, disposable aerosol-forming articles.

[0090] According to one aspect of this disclosure, an aerosol generation system may be provided, comprising the aerosol generation article as described above and an aerosol generation apparatus configured to receive the aerosol generation article.

[0091] The aerosol generating apparatus can be configured to generate an inhalable aerosol from at least a portion of an aerosol generating article, for example, the aerosol generating apparatus can be configured to heat at least a portion of the aerosol generating article to form an inhalable aerosol.

[0092] The aerosol generating apparatus may include a heater. The aerosol generating apparatus may also include means for applying tension to the aerosol forming matrix of the aerosol forming article, thereby allowing the aerosol forming matrix to expand.

[0093] The aerosol generating apparatus may include a mechanism for forming an aerosol-forming matrix configured to receive an aerosol-generated article in a deploying device.

[0094] The aerosol generation apparatus may include a indexing mechanism for an aerosol-forming matrix configured to receive the aerosol-generating article in a deployment apparatus. The deployment of the aerosol-forming matrix may be configured to be performed in intermittent steps.

[0095] The aerosol generating apparatus may include a display configured to indicate to a user how much aerosol generating matrix has been used, and alternatively, or additionally, to indicate how much aerosol generating matrix remains to be used. The display may show the number of uses. The display may indicate the number of uses of the aerosol generating article. The display may indicate the remaining number of uses of the aerosol generating article.

[0096] The aerosol generating apparatus may include a heater and a indexing mechanism configured to deploy an aerosol-forming matrix of an aerosol-generating article received in the apparatus. The indexing mechanism may be configured to move the aerosol-forming matrix through the heater in intermittent steps, for example, where the aerosol-forming matrix is ​​within the functional heating distance of the heater.

[0097] The aerosol generation system may include a heater. The heater may be a resistance heater, or may include a resistance heater. The heater may be a sensor for heating a sensor, or may include a sensor. Corresponding aerosol generation articles may include a sensor.

[0098] The heater can be configured to compress a portion of the aerosol forming matrix. The heater may include a first heating element, such as a first heating plate, and a second heating element, such as a second heating plate. The heater can be configured to compress a portion of the aerosol forming matrix between the first heating plate and the second heating plate. The portion of the aerosol forming matrix configured to be heated can be between 1 N and 50 N, for example, between 5 N and 30 N, such as under a compressive force between 7.5 N and 20 N.

[0099] The aerosol generating apparatus may include at least one sprocket for engaging with a perforation or sprocket hole defined in the aerosol forming matrix.

[0100] The aerosol generating apparatus may include a discharge shaft for receiving the aerosol forming matrix unwound from the aerosol generating article, or may be configured to receive the discharge shaft.

[0101] According to one aspect of this disclosure, a method for manufacturing aerosol-generating articles is provided. The method is applicable to the manufacture of aerosol-generating articles as described herein.

[0102] The method may include the following steps: providing a continuous sheet of aerosol forming matrix; cutting the continuous sheet of aerosol forming matrix to form an aerosol forming matrix for aerosol generating articles; and rolling up the aerosol forming matrix along its length to form a roll of aerosol forming matrix, thereby forming an aerosol generating article.

[0103] The method may further include the steps of forming a continuous sheet of aerosol forming matrix by: providing a first continuous sheet, providing a second continuous sheet, and providing a third continuous sheet, wherein at least one of the first continuous sheet, the second continuous sheet, and the third continuous sheet is a sheet comprising or composed of an aerosol forming material; texturing the second continuous sheet using a corrugating roller to form a continuous corrugated sheet; applying an adhesive to at least one of the continuous corrugated sheet or the first continuous sheet; applying a first side of the continuous corrugated sheet to the surface of the first continuous sheet; applying an adhesive to at least one of the continuous corrugated sheet and the third continuous sheet; and applying a second side of the continuous corrugated sheet to the surface of the third continuous sheet, thereby forming the continuous sheet of aerosol forming matrix. At least one of the first continuous sheet, the second continuous sheet, and the third continuous sheet may be a homogenized tobacco sheet.

[0104] The suction resistance (RTD) of a product or aerosol-generated product, or a component of a product or aerosol-generated product, is expressed in pressure units of “mm WG”, “mm water column”, or “mm H2O”.

[0105] Unless otherwise specified, draw resistance (RTD) is measured according to ISO 6565-2015. RTD refers to the pressure required to force air through the entire length of a component (such as an aerosol-forming matrix). The terms “pressure drop” or “draw resistance” for a component or article can also refer to “resistance to draw”. Such terms generally refer to measurements according to ISO 6565-2015 typically performed in a test at a temperature of about 22 degrees Celsius, a pressure of about 101 kPa (about 760 Torr), and a relative humidity of about 60%, at a volumetric flow rate of about 17.5 mL / s at the output or downstream end of the measuring component.

[0106] As used herein, the term "aerosol-generating article" may refer to an article that can generate or release aerosols.

[0107] As used herein, the term "aerosol forming matrix" can refer to a matrix capable of releasing aerosols or volatile compounds that can form aerosols. Such volatile compounds can be released by heating the aerosol forming matrix. An aerosol forming matrix may contain aerosol forming materials. Aerosol forming materials may be adsorbed, coated, impregnated, or otherwise loaded onto a carrier or support. As used herein, the terms "aerosol forming matrix" and "aerosol generating matrix" are used interchangeably.

[0108] As used herein, the term "aerosol generating apparatus" can refer to an apparatus used in conjunction with an aerosol generating article to enable the generation or release of aerosols.

[0109] As used herein, the term "aerosol generation system" refers to a combination of an aerosol generation apparatus and one or more aerosol generation articles for use with said apparatus. An aerosol generation system may include additional components, such as a charging unit for recharging the onboard power supply in an electrically operated or motorized aerosol generation apparatus.

[0110] As used herein, the term "aerosol forming agent" can refer to any suitable known compound or mixture of compounds that promotes the formation of aerosols in use. Aerosols can be dense and stable. Aerosols can be substantially heat-resistant to degradation at the operating temperatures of the aerosol forming matrix or the aerosol-generating article.

[0111] As used herein with reference to this invention, the term "nicotine" is used to describe nicotine, nicotine base, or nicotine salt.

[0112] As used herein with reference to the invention, the terms “proximal,” “distal,” “upstream,” and “downstream” are used to describe the relative positions of components or portions of the cylinder and aerosol generation system.

[0113] As used in this article, "sensor" refers to a conductive element that heats up when subjected to a changing magnetic field. This may be a result of eddy currents and / or hysteresis losses induced in the sensor element.

[0114] As used herein, the term "usage process" refers to an operational cycle of an aerosol generation system with a finite duration. A usage process can be a specific type of event that can be performed by the aerosol generation system. A usage process can be initiated by a user action. A usage process can be terminated after a predetermined period of time has elapsed since its initiation. During a usage process, the process can also be terminated once the monitored parameter has reached a threshold.

[0115] The invention is defined in the claims. However, a non-exhaustive list of non-limiting examples is provided below. Any one or more features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0116] Example Ex1. An aerosol generating article for generating aerosols, comprising a roll of an aerosol forming matrix defined by a length, a width, and a thickness, wherein the length is greater than the width and the width is greater than the thickness, wherein the thickness is greater than or equal to 0.5 mm, and wherein at least a portion of the aerosol forming matrix is ​​rolled up along its length.

[0117] Example Ex2. An aerosol generating article according to Example Ex1, which is used with an aerosol generating apparatus configured to heat a portion of the aerosol generating matrix, for example wherein the aerosol generating article is configured to be inserted into or engaged with the aerosol generating apparatus.

[0118] Example Ex3. An aerosol-generating article according to any of the foregoing examples, wherein the roll of the aerosol-forming material is substantially cylindrical and / or has a height equal to the width of the aerosol-forming matrix.

[0119] Example Ex4. An aerosol-generating article according to any of the preceding examples, wherein the thickness of the aerosol-forming matrix is ​​between 0.5 mm and 15 mm, for example between 1 mm and 8 mm, for example between 2 mm and 6 mm, for example about 2 mm, or about 2.5 mm, or about 3 mm, or about 4 mm.

[0120] Example Ex5. An aerosol-generating article according to any of the foregoing examples, wherein the length of the aerosol-forming matrix in the unfolded state is between 10 mm and 10,000 mm, for example between 20 mm and 800 mm, for example between 30 mm and 600 mm, for example between 150 mm and 500 mm.

[0121] Example Ex5a. An aerosol-generating article according to any of the foregoing examples, wherein the aerosol-forming matrix is ​​configured such that the length of the portion used in a single use in the unfolded state is between 10 mm and 100 mm, for example between 20 mm and 80 mm, for example between 30 mm and 60 mm, for example about 30 mm, or about 35 mm, or about 40 mm, or about 50 mm.

[0122] Example Ex6. An aerosol-generating article according to any of the preceding examples, wherein the width of the aerosol-forming matrix is ​​between 5 mm and 60 mm, for example between 10 mm and 50 mm, for example between 15 mm and 40 mm, for example about 15 mm, or about 20 mm, or about 25 mm, or about 30 mm.

[0123] Example 6a. An aerosol-generating article according to any of the preceding examples, wherein the aerosol-generating matrix has a Young's modulus between 10 MPa and 1000 MPa, for example between 30 MPa and 500 MPa.

[0124] Example Ex7. An aerosol-forming article according to any of the foregoing examples, wherein the aerosol-forming matrix comprises two or more layers, such as two or more layers laminated together, for example, wherein the aerosol-forming matrix comprises at least a first planar layer forming the upper surface of the aerosol-forming matrix and a second planar layer forming the lower surface of the aerosol-forming matrix.

[0125] Example Ex8. An aerosol-generating article according to Example Ex7, wherein the aerosol-forming matrix comprises a first planar layer, a second planar layer, and an intermediate layer or separation layer disposed between the first planar layer and the second planar layer, wherein at least one of the first planar layer, the second planar layer, and the intermediate layer or separation layer comprises or is composed of an aerosol-forming material.

[0126] Example Ex9. An aerosol-generating article according to Example Ex8, wherein the intermediate layer or the separating layer is a corrugated layer, for example, wherein the aerosol-forming matrix includes a first planar layer, a second planar layer and a corrugated layer disposed between the first planar layer and the second planar layer, wherein at least one of the first planar layer, the second planar layer and the corrugated layer includes or is composed of an aerosol-forming material.

[0127] Example Ex10. An aerosol-forming article according to Example Ex9, wherein the corrugations are arranged perpendicular to the length direction of the aerosol-forming matrix and parallel to the width direction of the aerosol-forming matrix, for example, such that the corrugations are arranged perpendicular to the roll-up direction of the aerosol-forming matrix.

[0128] Example Ex11. An aerosol-generating article according to any of the foregoing examples, wherein the aerosol-forming matrix has, in its unfolded state, a length defined by an x-dimensional dimension extending in the x-direction, a width defined by a y-dimensional dimension extending in the y-direction, and a height or thickness defined by a z-dimensional dimension extending in the z-direction.

[0129] Example Ex12. An aerosol-forming article according to Example Ex11, wherein the airflow path is defined to pass through the aerosol-forming matrix, for example, wherein a low-resistance airflow path is defined to pass through the matrix, for example, wherein the aerosol-forming matrix has a suction resistance (RTD) of less than 80 mm H2O, or less than 40 mm H2O, or less than 30 mm H2O along the airflow path.

[0130] Example Ex13. An aerosol-generated article according to Example Ex11 or Ex12, wherein an airflow path extends across the matrix from one side edge to the other on the y-dimensional side, for example, wherein the airflow path extends substantially in the y-direction.

[0131] Example Ex14. An aerosol-generated article according to Example Ex11 or Ex12, wherein an airflow path extends through the matrix from one end to the other on the x-axis, for example, wherein the airflow path extends substantially in the x-direction.

[0132] Example Ex15. An aerosol-generating article according to any of the preceding examples, wherein the radius of curvature of the aerosol-forming matrix at the innermost portion of the roll is less than 4 times the thickness of the aerosol-forming matrix, for example less than 3.5 times the thickness, or less than 3 times the thickness, or less than 2.5 times the thickness, or less than 2 times the thickness.

[0133] Example Ex16. An aerosol-generating article according to any of the preceding examples, wherein the radius of curvature of the aerosol-forming matrix at the innermost portion of the roll is between 2 mm and 30 mm, for example between 2.5 mm and 20 mm, for example between 3 mm and 15 mm.

[0134] Example Ex17. An aerosol-generating article according to any of the preceding examples, wherein the aerosol-forming matrix is ​​wound onto a reel.

[0135] Example Ex18. An aerosol-generating article according to Example Ex17, wherein the aerosol-forming matrix is ​​wound onto a spool or shaft of a roll, wherein the maximum thickness or diameter of the spool or shaft is between 4 mm and 60 mm, for example between 5 mm and 40 mm, for example between 6 mm and 30 mm.

[0136] Example Ex19. An aerosol-generating article according to any of the foregoing examples, wherein the roll of the aerosol-forming matrix is ​​located within a shell, for example, a substantially cylindrical shell.

[0137] Example Ex20. An aerosol-forming article according to Example Ex19, wherein the aerosol-forming matrix is ​​wound onto a spool or shaft located in the substantially radially central portion of the shell, such as the cylindrical shell.

[0138] Example Ex21. An aerosol-forming article according to any of the foregoing examples includes a plurality of perforations or sprocket holes for tensioning the aerosol-forming matrix, for example for facilitating the winding and / or unwinding of a roll of the aerosol-forming matrix, wherein the perforations or sprocket holes are arranged for engagement with a mechanical device such as a sprocket.

[0139] Example Ex22. An aerosol-forming article according to Example Ex21, wherein the plurality of perforations or sprocket holes are arranged in a row extending in the x direction of the aerosol-forming matrix, for example, in two rows extending in the x direction, the two rows being spaced apart in the y direction.

[0140] Example Ex23. An aerosol generation system comprising an aerosol generation article according to any of the foregoing examples and an aerosol generation apparatus configured to receive the aerosol generation article.

[0141] Example Ex24. An aerosol generating system according to Example Ex23, wherein the aerosol generating apparatus is configured to generate an inhalable aerosol from at least a portion of the aerosol generating article, for example, wherein the aerosol generating apparatus is configured to heat at least a portion of the aerosol generating article to form an inhalable aerosol.

[0142] Example Ex25. An aerosol generation system according to Example Ex23 or Ex24, wherein the aerosol generation apparatus includes a heater and means for applying tension to the aerosol forming matrix of the aerosol forming article so that the aerosol forming matrix can be deployed.

[0143] Example Ex26. An aerosol generation system according to Example Ex25, wherein the aerosol generation apparatus includes a mechanism configured to deploy an aerosol forming matrix of the aerosol generation article received in the apparatus.

[0144] Example Ex27. An aerosol generation system according to Example Ex25 or Ex26, wherein the aerosol generation apparatus includes a indexing mechanism configured to deploy an aerosol forming matrix of the aerosol generation article received in the apparatus, the deployment of the aerosol forming matrix being configured to be performed in discontinuous steps.

[0145] Example Ex28. An aerosol generation system according to any one of Examples Ex25 to Ex27, wherein the aerosol generation apparatus includes a heater and an indexing mechanism configured to deploy an aerosol forming matrix of the aerosol generation article received in the apparatus, the indexing mechanism being configured to move the aerosol forming matrix through the heater in intermittent steps, for example, wherein the aerosol forming matrix is ​​within the functional heating distance of the heater.

[0146] Example Ex29. An aerosol generating system according to any one of Examples Ex23 to Ex28, comprising a heater, wherein the heater is a resistance heater or comprises a resistance heater, or wherein the heater is a sensor for a heating sensor or comprises a sensor.

[0147] Example Ex30. An aerosol generating system according to any one of Examples Ex24 to Ex29, wherein the aerosol generating apparatus includes at least one sprocket for engaging with a perforation or sprocket hole defined in the aerosol forming matrix.

[0148] Example Ex31. An aerosol generation system according to any one of Examples Ex24 to Ex30, wherein the aerosol generation apparatus includes a discharge shaft for receiving or configured to receive an aerosol forming matrix unwound from the aerosol generation article.

[0149] Example Ex32: A method of manufacturing an aerosol-forming article according to any of the foregoing examples, comprising the steps of: providing a continuous sheet of an aerosol-forming matrix; cutting the continuous sheet of the aerosol-forming matrix to form the aerosol-forming matrix for the aerosol-forming article; and rolling the aerosol-forming matrix along its length to form a roll of the aerosol-forming matrix.

[0150] Example Ex33: The method according to Example Ex32 includes forming a continuous sheet of aerosol forming matrix by: providing a first continuous sheet, providing a second continuous sheet, and providing a third continuous sheet, wherein at least one of the first continuous sheet, the second continuous sheet, and the third continuous sheet is a sheet comprising or composed of an aerosol forming material; using a corrugating roller to texture the second continuous sheet to form a continuous corrugated sheet; applying an adhesive to at least one of the continuous corrugated sheet or the first continuous sheet; applying a first side of the continuous corrugated sheet to the surface of the first continuous sheet; applying an adhesive to at least one of the continuous corrugated sheet and the third continuous sheet; and applying a second side of the continuous corrugated sheet to the surface of the third continuous sheet, thereby forming the continuous sheet of the aerosol forming matrix.

[0151] Example Ex34: According to the method of Example Ex32 or Ex33, at least one of the first continuous sheet, the second continuous sheet and the third continuous sheet is a homogenized tobacco sheet. Attached Figure Description

[0152] The examples will now be described further with reference to the accompanying drawings, in which:

[0153] Figure 1a A schematic perspective view of an aerosol-generated article according to a first embodiment of the present disclosure is shown;

[0154] Figure 1b A schematic perspective view of the aerosol-forming matrix of the first embodiment in its unfolded state is shown;

[0155] Figure 2a A schematic perspective view of a portion of an aerosol-generated article according to a second embodiment is shown;

[0156] Figure 2b A schematic cross-sectional view of a portion of an aerosol-generated article according to the second embodiment is shown;

[0157] Figure 3 A schematic perspective view of an aerosol-generated article according to a third embodiment is shown;

[0158] Figure 4aA schematic cross-sectional view of an aerosol generation system including an aerosol-generating article is shown.

[0159] Figure 4b It shows Figure 4a A schematic cross-sectional plan view of the aerosol generation system in the diagram; and

[0160] Figure 5 A schematic diagram of the apparatus used in manufacturing an aerosol-generating article according to the second embodiment is shown. Detailed Implementation

[0161] Figure 1a A schematic perspective view of an aerosol generating article 10 according to a first embodiment of the present disclosure is shown. Figure 1b A schematic perspective view of the aerosol forming matrix 12 of the first embodiment in its unfolded state is shown.

[0162] like Figure 1a As shown, the aerosol generating article 10 includes an aerosol generating matrix 12, which is rolled up along its length to form a rolled-up aerosol generating article 10. The aerosol generating matrix 12 is defined by its length, width (W), and thickness (T). The length is greater than the width (W), and the width (W) is greater than the thickness (T). The thickness (T) of the aerosol generating matrix is ​​greater than or equal to 0.5 mm. In this preferred embodiment, the aerosol generating matrix has a thickness (T) between 0.5 mm and 15 mm, preferably 1.5 mm. The width (W) of the aerosol generating matrix is ​​between 5 mm and 60 mm, preferably 30 mm.

[0163] like Figure 1b As shown, the aerosol forming matrix 12 in its unfolded state has a length (L). The length (L) is between 150 mm and 500 mm.

[0164] The aerosol generating article 10 is configured for use with an aerosol generating apparatus configured to heat a portion of the aerosol forming matrix. The aerosol generating article 10 is configured to be inserted into or engaged with the aerosol generating apparatus. During use, only a portion of the aerosol forming matrix is ​​heated. The portion of the aerosol forming matrix that will be heated during a single use has a partial length (LP) between 30 mm and 60 mm, preferably 50 mm, in its unfolded state. This portion of the aerosol forming matrix may be referred to as the tail of the roll. Figure 1a The diagram shows that the partial length (LP) is less than the width (W) in magnitude. However, it should be understood that the partial length (LP) may be equal to the width (W) in magnitude or preferably greater than the width in magnitude.

[0165] The aerosol generating article 10 includes a roll 14 of a substantially cylindrical aerosol forming matrix. The radius of curvature of the aerosol forming matrix 12 at the innermost portion of the roll 14 is less than four times the thickness of the aerosol forming matrix 12. In this example, the radius of curvature is between 3 mm and 15 mm.

[0166] The aerosol forming matrix 12 has a Young's modulus between 30 MPa and 500 MPa.

[0167] In use, air flows through the aerosol forming matrix 12. The airflow path is defined to pass through the aerosol forming matrix 12. The airflow path is defined to pass through the portion of the aerosol forming matrix configured to be heated during use. The aerosol forming matrix may, for example, have a suction resistance (RTD) of less than 80 mmH2O, less than 40 mmH2O, or less than 30 mmH2O.

[0168] The aerosol forming matrix 12 contains an aerosol forming material. A suitable aerosol forming material may be homogenized tobacco.

[0169] The aerosol forming material can be any suitable aerosol forming material. For illustrative purposes, the composition of a suitable aerosol forming material may be as follows. Percentages are given as a weight percentage relative to the product in its final state. The aerosol forming material may have about 5% to 25%, preferably about 7% to 15%, of moisture in the final product state. The aerosol forming material may also include the following:

[0170] 1. Tobacco leaves; for example, a blend of tobacco leaves comprising about 15% to 45%, preferably about 20% to 35%, including at least one of the following tobacco types: flue-cured tobacco; sun-cured tobacco; aromatic tobacco. The tobacco material is ground and graded to a particle size of about 100 to 380 mesh, preferably about 170 to 320 mesh.

[0171] 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.

[0172] 3. Tobacco fiber; for example, about 5% to 20%, preferably about 7% to 15%, of any type of tobacco or tobacco blend as a filler. The tobacco fiber is preferably derived from stems and / or stalks and is graded into fibers with a length of about 10 to 350 μm, preferably about 10 to 180 μm.

[0173] 4. A 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 pectin; guar gum, locust bean gum, hydroxyethyl and / or hydroxypropyl derivatives such as these; starch, such as modified or derivatized starch; alginate; methyl, ethyl, ethylhydroxymethyl and carboxymethyl cellulose; dextran; and xanthan gum. Guar gum is a preferred binder.

[0174] 5. An aerosol forming agent; for example, about 5% to 35%, preferably about 10% to 25% of an aerosol forming agent. Suitable aerosol forming agents known in the art include: glycerol; monohydric alcohols, such as menthol; polyhydric alcohols, such as triethylene glycol; esters of polyhydric alcohols, such as mono-, di-, or triacetic acid esters; and aliphatic esters of mono-, di-, or polycarboxylic acids, such as dimethyl esters of these.

[0175] "Tobacco type" refers to one of the different tobacco varieties, for example, based on the different maturation processes that tobacco undergoes before being further processed into tobacco products.

[0176] To form an aerosol-forming material, various components can be mixed together and cast into a sheet of desired thickness. The sheet can then be dried to suit processing for forming the aerosol-forming matrix 12.

[0177] For illustrative purposes, another aerosol forming material (which may be suitable as the aerosol forming material sheet in the above specific embodiments) may have the following composition. Percentages are given as weight percentages relative to the product in its final state. The aerosol forming material may comprise:

[0178] 1. An aerosol forming agent, such as glycerol; for example, about 10% to 40%, preferably about 20% to 30%.

[0179] 2. Organic fibers; for example, about 10% to 30%, preferably about 15% to 25%, of any plant-derived variety, suitable and of purity meeting applicable FDA F&B grade requirements, as commonly available in the market. For example, organic fibers may be derived from cellulose, cotton, wood, or tea plant-derived varieties that are byproducts and by-processing wastes of the F&B tea industry. Organic fibers preferably have a length of about 10 to 400 μm, preferably about 10 to 200 μm.

[0180] 3. Organic plant-derived glycerin; for example, about 15% to 55%, preferably about 20% to 35% of plant-derived materials, such as clove, echinacea, fennel, ginger, hawthorn berries, elderberry fruit, horsemint, mullein leaves, nettle, plantain, turmeric, yarrow and compounds thereof.

[0181] 4. Organic plant-derived extracts; for example, about 1% to 15%, preferably about 2% to 7%, of any previously mentioned plant-derived material, and menthol (dl-menthol, C10H20O, 2-isopropyl-5-methylcyclohexanol) and p-menthane-3-ol obtained from Chaerophyllum macrospermum, Mesosphaerum sidifolium or other related plant varieties, which are any secondary alcohols such as diastereomers of 5-methyl-2-(propyl-2-yl)cyclohexane-1-ol.

[0182] Alternatively, such aerosol forming materials may also contain about 0.5% to 5%, preferably about 1% to 3%, of plant-derived essential oils, such as palm oil, coconut oil and wood-based essential oils.

[0183] Figure 2a A schematic perspective view of a portion of an aerosol generating article according to a second embodiment is shown. The aerosol generating article 100 includes an aerosol forming matrix 102. The aerosol forming matrix 102 includes a planar upper layer 110, a planar lower layer 130, and an intermediate or separating layer 120 disposed between the upper layer 110 and the lower layer 130.

[0184] The upper planar layer 110 is formed of a paper sheet with a thickness between 0.1 and 0.5 mm. The lower planar layer 130 is formed of a paper sheet with a thickness between 0.1 and 0.5 mm. The intermediate layer 120 includes corrugated elements formed of a corrugated sheet of aerosol-forming material. A suitable aerosol-forming material may be homogenized tobacco. Therefore, in this example, the intermediate layer 120 includes a corrugated sheet of homogenized tobacco material. The intermediate layer 120 may include other suitable aerosol-forming materials.

[0185] Intermediate layer 120 includes an aerosol forming agent 140, such as a viscous liquid or gel. The aerosol forming agent 140 can be aerosolized by heating the aerosol forming matrix. A corrugated sheet of aerosol forming material can be impregnated with the aerosol forming agent 140. The aerosol forming agent 140 can be present in the intermediate layer 120 between the grooves of the corrugated elements, the spaces between the grooves of the corrugated elements being referred to as channels.

[0186] The aerosol-forming article 100 includes perforations, such as sprocket holes 180. The sprocket holes 180 include a plurality of openings extending through the thickness of the aerosol-forming matrix. The sprocket holes 180 extend from the outer surface of the upper layer 110 to the outer surface of the lower layer 130. The sprocket holes are configured to engage with a sprocket to align the aerosol-forming matrix when the aerosol-forming matrix 102 is rolled into the aerosol-forming article, and alternatively or additionally, when the aerosol-forming matrix is ​​unrolled from the aerosol-forming article. The plurality of sprocket holes 180 are arranged in a row extending along the length (in the unrolled state) of the aerosol-forming matrix, for example, in two rows extending along the length (in the unrolled state). The two rows of sprocket holes 180 are spaced apart across the width of the aerosol-forming matrix. For example, the first row of sprocket holes is adjacent to a first edge of the outer surface of the upper layer 110 and a first edge of the outer surface of the lower layer 130, and the second row of sprocket holes 180 is adjacent to a second edge of the outer surface of the upper layer 110 and a second edge of the outer surface of the lower layer 130. Wherein, the first edge of the outer surface of the upper layer 110 spans the width of the aerosol forming matrix and is spaced apart from the second edge of the outer surface of the upper layer 110, and the first edge of the outer surface of the lower layer 130 spans the width of the aerosol forming matrix and is spaced apart from the second edge of the outer surface of the lower layer 130.

[0187] Figure 2b A schematic cross-sectional view of a portion of an aerosol-generated article according to a second embodiment is shown. Figure 2b A corrugated sheet of aerosol forming material is shown. The corrugations have a amplitude 122 between 0.1 mm and 0.5 mm, and a wavelength 124 between 2 mm and 4 mm. The aerosol forming material sheet forming the intermediate layer 120 has a thickness between 0.1 mm and 0.5 mm.

[0188] The intersections 170 and 160 between the upper layer 110 and the middle layer 120, and between the lower layer 130 and the middle layer 120, include adhesives connecting the respective layers.

[0189] The corrugation of the intermediate layer 120 forms a first set of transverse channels 172 defined by the upper layer 110 and the intermediate layer 120, and a second set of transverse channels 162 defined by the lower layer 130 and the intermediate layer 120. The first set of transverse channels 172 and the second set of transverse channels 162 extend across the width of the aerosol forming matrix 102. The transverse channels 172, 162 define airflow paths through the aerosol forming matrix 102. Therefore, the airflow paths pass through both sides of the corrugated sheet of the aerosol forming material. The porosity of the aerosol forming matrix along the airflow paths is approximately 90%. This provides very low suction resistance of less than 30 mm H2O.

[0190] The corrugations of the intermediate layer 120 are transverse to the length of the aerosol-forming article. Therefore, the corrugations are perpendicular to the roll-up direction of the aerosol-forming matrix 102 in the aerosol-forming article. Consequently, the corrugations can provide compressive strength to the aerosol-forming matrix without impairing its ability to be rolled up along its length.

[0191] The corrugated sheet 120 of the aerosol forming material can be any suitable aerosol forming material sheet as described in the first embodiment.

[0192] Figure 3 A schematic perspective view of an aerosol generating article according to a third embodiment is shown. The aerosol forming matrix 312 of the third embodiment is described below. However, the aerosol generating article of the third embodiment may include any suitable aerosol forming matrix. For example, the aerosol generating article may include the aerosol forming matrix 12 described with respect to the first embodiment, or the aerosol forming matrix 102 described with respect to the second embodiment.

[0193] Except as described below, the aerosol forming matrix 312 is the same as the aerosol forming matrix 12 of the first embodiment.

[0194] The aerosol generating article 300 includes a swivel 321. An aerosol generating matrix 312 is wound onto the swivel 321. The swivel 321 has a maximum diameter between 6 mm and 30 mm. The swivel 321 is configured to rotate. The aerosol generating matrix 312 can be wound onto and unwound from the swivel 321.

[0195] The aerosol-forming matrix roll 314 is located within a generally cylindrical shell 316. The pivot 321 is located at the generally radial center of the shell 316.

[0196] The cover 322 is configured to secure the roll 314 of the aerosol forming matrix within the cover 316. The pivot 321 extends into the cover 322.

[0197] The shell 316 includes a roll window 382. The roll window 382 allows the aerosol forming matrix or a section of the aerosol forming matrix to be extracted from the shell 316.

[0198] The aerosol forming matrix 312 includes a plurality of sprocket holes 380 for engagement with corresponding sprockets. The plurality of sprocket holes 380 extend in two rows along the length of the aerosol forming matrix (in the unfolded state). The sprocket holes 380 are the same as the sprocket holes 180 described with reference to the second embodiment.

[0199] The sprocket hole 380 is suitable for tensioning the aerosol forming matrix. The sprocket hole 380 facilitates the winding and unwinding of the aerosol forming matrix. During the manufacture of the aerosol-generated article, the sprocket hole can be used to engage with a sprocket to facilitate the movement of the aerosol forming matrix through the manufacturing process. The sprocket hole also facilitates the winding of the aerosol forming matrix 312 onto or onto the shaft 323. During the use of the aerosol-generated article, the sprocket hole is arranged to engage with a sprocket in the aerosol generating apparatus to unwind or unwind the aerosol forming matrix 312 from the shaft 323.

[0200] Figure 4a A schematic cross-sectional view of an aerosol generating system including an aerosol generating article is shown. The aerosol generating system 500 includes the aerosol generating article 310 of the third embodiment; however, any suitable aerosol generating article can be configured for use in the aerosol generating system. For example, the aerosol generating system may include the aerosol generating article 10 of the first embodiment or the aerosol generating article 100 of the second embodiment.

[0201] The aerosol generation system 500 includes an aerosol generation device 600. The aerosol generation device 600 includes a housing 680. The housing 680 includes an opening for receiving an aerosol-generated article 300. The housing 680 includes a door 640 configured to cover the opening. The door 640 is openable via a latch 690. The door 640 is openable to an angle 645 in the range of 45° to 120°, preferably 60° to 90°. The door 640 pivots automatically about one end of the device at a spring-loaded hinge 650. Once the door 640 is open, the aerosol-generated article 300 can be loaded into the device 600.

[0202] The aerosol generating apparatus 600 includes a device sprocket 620 configured to engage with a sprocket bore of an aerosol generating article 300. The sprocket 620 has teeth 622 configured to engage with the sprocket bore and help maintain alignment of the aerosol forming matrix. The sprocket 620 is rotatable to convey the aerosol forming matrix from a shaft 321 of the aerosol forming article to a discharge shaft 630 of the aerosol generating apparatus 600. The discharge shaft 630 includes a groove 631 for receiving the aerosol forming matrix 312. The discharge shaft 630 is rotatable to unfold the aerosol forming matrix 312 from the shaft 321. As the aerosol forming matrix 312 unfolds from the shaft 321, it is wrapped around the discharge shaft 630. The discharge shaft 630 includes a shaft rod for a user to rotate the discharge shaft. Alternatively, the discharge shaft 630 includes an electric motor for rotating the discharge shaft 630.

[0203] Device 600 is an elongated aerosol generating device extending between a proximal end 641 and a distal end 642. The proximal end 641 includes a mouthpiece 670. Device 600 includes a battery and a controller (not shown), and a heater 700 located within a housing 680. The controller controls the power supply from the battery to the heater 700. In this embodiment, the heater 700 includes two heating plates 710, 712. The first heating plate 710 is located within the housing 680 and configured to be positioned on a first side of the aerosol generating matrix in use. The second heating plate 712 is positioned on a door 640 and configured to be positioned on a second side of the aerosol generating matrix in use. The first side of the aerosol generating matrix is ​​opposite to the first side. For example, when the aerosol generating article includes an aerosol generating matrix having an upper and a lower layer, the first side may include the upper layer, and the second side may include the lower layer.

[0204] The airflow path is defined to pass through the aerosol generating device 600 and the aerosol forming matrix 312. The aerosol generating device is configured to allow air to flow into the device through an air inlet. The mouthpiece 670 includes an air outlet.

[0205] Figure 4b The airflow path is shown in more detail. Figure 4b It shows Figure 4a A schematic cross-sectional plan view of the aerosol generation system in the image. Figure 4b As shown, the aerosol generating device 600 includes an air inlet 690. In this embodiment, the air inlet is located in the side wall of the housing 680. The aerosol generating device 600 also includes an air outlet 675. The air outlet 675 is located in the mouthpiece 670. The airflow path is defined between the air inlet 690 and the air outlet 675. Air can enter the aerosol generating system 500 via the air inlet 690 and exit the aerosol generating system 500 via the air outlet 675.

[0206] The airflow path is defined as passing through the aerosol forming matrix 312. In particular, the airflow path is defined as passing through the unfolded portion of the aerosol-generated article. Figure 4b Only a portion of the aerosol-generating article 300 is shown positioned between the first heating plate 710 and the second heating plate 712. Figure 4b An example of an airflow path is shown; however, it should be understood that any suitable airflow path can be used. For example, the airflow path can be adjusted, for instance, by repositioning the air inlet 690.

[0207] To use the aerosol generation system 500, the user opens door 640 and inserts the aerosol-generated article 300 through the opening of the aerosol generation device 600. The user aligns the rolled end of the aerosol-forming matrix 312 with the sprocket 620, such that the sprocket teeth 622 engage with the sprocket hole of the aerosol-forming matrix. The rolled end of the aerosol-forming matrix is ​​inserted into the groove 631 of the discharge shaft 630. The user closes door 640, and the aerosol generation system 500 is ready for use.

[0208] When the door 640 is closed, the second heating plate 712 contacts the aerosol forming matrix 312. Therefore, a portion of the aerosol forming matrix 312 is located between the first heating plate 710 and the second heating plate 712. This portion of the aerosol forming matrix 312 is positioned adjacent to the heater 700. This portion of the aerosol forming matrix 312, located between the first heating plate 710 and the second heating plate 712, is configured to be heated during use of the aerosol generation system 500. The portion of the aerosol forming matrix configured to be heated by the heater 700 contacts the first heating plate 710 and the second heating plate 712 and can be subjected to a compressive force between 7.5 N and 20 N applied by the first heating plate 710 and the second heating plate 712.

[0209] The user then activates the aerosol generating device 600. The user can activate the device via a button. The button may be electrically connected to a battery and a controller. The device may include sensors, such as a puff sensor, configured to detect puffing, such as when the user inhales through the device's mouthpiece. The puff sensor may be electrically connected to the battery and a controller. When the controller receives a signal indicating that the user has activated the aerosol generating device, for example via the button or the puff sensor, the controller is configured to activate the heater 700.

[0210] Heater 700 is configured to heat the portion of the aerosol-forming article located between heating plates 710 and 712 via heating plates 710 and 712. Heater 700 raises the temperature of a portion of the aerosol-forming article to a temperature between 200 and 400 degrees Celsius. Volatile components in the aerosol-forming matrix are vaporized. The vapor condenses to form an aerosol for inhalation by a user. In this embodiment, heater 700 is a resistance heater. However, in other embodiments, heater 700 may be an induction heater, wherein the heating plates are sensors configured to heat sensor material located in the aerosol-forming matrix.

[0211] In use, the user inhales through the mouthpiece 670 of the aerosol generating device 600. Air is drawn into the aerosol generating system 500 via the air inlet 690. The air enters the aerosol forming matrix 312 and cools the vapor generated by the volatile components of the aerosol generating matrix. The cooled vapor condenses to form an aerosol. The user inhales the aerosol by inhaling through the air outlet 675 of the aerosol generating system 500. The process stops once the volatile components of the aerosol forming material have been depleted. The process can be stopped after a predetermined number of inhalations or after a predetermined time period.

[0212] After use, the depleted, used portion of the aerosol-forming matrix 312 between the heating plates 710 and 712 is removed from the heatable range of the heater 700. The discharge shaft 630 is rotated mechanically by the user or by a motor to pull the aerosol-forming matrix 312 toward the discharge shaft 320. As the discharge shaft 630 rotates, the depleted, used portion of the aerosol-forming matrix is ​​rolled up around the discharge shaft 603, so that the used portion of the aerosol-forming matrix is ​​stored on the discharge shaft 630. The rotation of the discharge shaft 630 pulls the unused portion of the aerosol-forming matrix from the rolled-up portion of the aerosol-generated article and into the region adjacent to the heater 700, between the first heating plate 710 and the second heating plate 712. The aerosol-generating apparatus 600 may include a usage indicator configured to display the remaining number of uses of the aerosol-generated article. The indicator is configured to update when the portion of the aerosol-forming matrix has moved from the heater 700 to the discharge shaft 630.

[0213] After a new, unused portion of the aerosol-forming matrix is ​​positioned between heating plates 710 and 712, the aerosol generation system is ready for another use process.

[0214] After the aerosol generating article 300 is exhausted, for example after a predetermined number of uses has been completed, the user can then open the door 640 and remove the aerosol generating article 300 from the aerosol generating device 600.

[0215] Figure 5 A schematic diagram of the apparatus used in manufacturing an aerosol-generating article according to the second embodiment is shown.

[0216] Figure 5 An apparatus 800 is shown that can be used to manufacture an aerosol forming matrix 102. Continuous sheets of three main components of the aerosol forming matrix are provided: a continuous paper sheet for forming a lower surface 130, a continuous paper sheet for forming an upper surface 110, and a continuous aerosol forming material sheet for forming a corrugated intermediate layer 120.

[0217] The following steps can occur during the manufacture of the aerosol-forming matrix:

[0218] The process begins with the creation of a single-sided corrugated structure. A roll of first continuous sheet 130 is loaded via a single-sided sheet roll 811 and fed through a series of rollers in which the first continuous sheet is kept taut and becomes more flexible through heat applied by a preheating roller 812. Simultaneously, a corrugated interlayer 120 is formed using a series of corrugated rollers 818a and 819a, which shape the desired profile into the corrugated interlayer 120.

[0219] The continuous matrix sheet for the corrugated layer is fed under tension to a pair of corrugated or ribbed rollers 818a and 819a. The corrugated rollers 818a and 819a texturize the continuous matrix sheet of the corrugated layer to introduce corrugations of desired wavelength and amplitude.

[0220] Adhesive 815 (such as glue) is applied to the peaks of the corrugations via a first adhesive applicator (i.e., glue applicator roller 814). The corrugated sheet is then brought into contact with a first continuous sheet 130, such that the glue bonds the corrugated peaks in the corrugated intermediate layer 120 to the first continuous sheet 130. At this stage, the material is referred to as a single-sided corrugated sheet and is held within a temporary retaining bridge before moving to the next stage of the process.

[0221] In the next stage of the process, an aerosol forming agent may be applied to the corrugated intermediate layer 120 via an aerosol forming agent applicator 833, which may spray or apply the aerosol forming agent to the corrugated intermediate layer 120.

[0222] Next, another layer, namely the second continuous sheet 110, is applied to the corrugated intermediate layer 120 on the side opposite to the first continuous sheet 130. The second continuous sheet 110 is bonded to the corrugated intermediate layer 120 under steam and pressure applied via the steam applicator 829 and the pressure plate 830, thereby forming a double-sided planar consumable aerosol forming matrix.

[0223] Then the sprocket hole can be added using the stamping roller 831.

[0224] Optionally, additional aerosol forming agent can then be injected into the grooved layer channels via injection point 835, after which the sheet can be cut into the desired planar consumable shape by a tool.

[0225] In the final stage, the planar consumable can be rolled into an Archimedean spiral at process step 832 for subsequent use to form a rolled aerosol-formed article.

[0226] For the purposes of this specification and the appended claims, unless otherwise stated, all figures representing quantities, quantities, percentages, etc., shall be understood to be modified by the term "about" in all cases. Furthermore, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically listed herein. Thus, in this context, the number A is understood to be A ± 10% of A. In this context, the number A can be considered to include a value within the general standard error for the measurement of the attribute modified by the number A. In some cases used in the appended claims, the number A may deviate from the percentages listed above, provided that the amount of deviation from A does not materially affect the essential and novel features of the claimed invention. Furthermore, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically listed herein.

Claims

1. An aerosol generating article comprising a roll of an aerosol forming matrix for generating an aerosol, the aerosol forming matrix being defined by a length, a width, and a thickness, wherein the length is greater than the width and the width is greater than the thickness, wherein the thickness is greater than or equal to 1.5 mm, and wherein at least a portion of the aerosol forming matrix is ​​rolled up along its length.

2. The aerosol generating article of claim 1, for use with an aerosol generating apparatus configured to heat a portion of the aerosol forming matrix, for example wherein the aerosol generating article is configured to be inserted into or engaged with the aerosol generating apparatus.

3. The aerosol-generating article according to any of the preceding claims, wherein the thickness of the aerosol-forming matrix is ​​between 1.5 mm and 15 mm, the length of the aerosol-forming matrix in the unfolded state is between 30 mm and 500 mm, and the width of the aerosol-forming matrix is ​​between 5 mm and 60 mm.

4. The aerosol-forming article according to any of the preceding claims, wherein the aerosol-forming matrix comprises two or more layers, such as two or more layers laminated together, for example, wherein the aerosol-forming matrix comprises at least a first planar layer forming the upper surface of the aerosol-forming matrix and a second planar layer forming the lower surface of the aerosol-forming matrix.

5. The aerosol-generating article according to claim 4, wherein the aerosol-forming matrix comprises a first planar layer, a second planar layer, and an intermediate layer disposed between the first planar layer and the second planar layer, and at least one of the first planar layer, the second planar layer, and the intermediate layer comprises or is composed of an aerosol-forming material.

6. The aerosol-generating article according to claim 5, wherein the intermediate layer is a corrugated layer.

7. The aerosol-generating article according to claim 6, wherein the corrugations are arranged perpendicular to the length direction of the aerosol-forming matrix.

8. The aerosol-generating article according to any of the preceding claims, wherein the aerosol-forming matrix has, in its unfolded state, a length defined by an x-dimensional dimension extending in the x-direction, a width defined by a y-dimensional dimension extending in the y-direction, and a height or thickness defined by a z-dimensional dimension extending in the z-direction.

9. The aerosol generating article of claim 8, wherein the airflow path is defined through the aerosol forming matrix, for example, wherein a low-resistance airflow path is defined through the matrix, for example, wherein the aerosol forming matrix has a suction resistance (RTD) of less than 30 mm H2O along the airflow path.

10. The aerosol-generating article according to any of the preceding claims, wherein the radius of curvature of the aerosol-forming matrix at the innermost portion of the roll is less than four times the thickness of the aerosol-forming matrix, and / or wherein the radius of curvature of the aerosol-forming matrix at the innermost portion of the roll is between 2 mm and 30 mm.

11. The aerosol-generating article according to any of the preceding claims, wherein the aerosol-forming matrix is ​​wound onto a reel.

12. The aerosol-generating article according to any of the preceding claims, wherein the roll of the aerosol-forming matrix is ​​located within a shell, for example, a substantially cylindrical shell.

13. The aerosol generating article according to any of the preceding claims, comprising a plurality of perforations or sprocket holes for tensioning the aerosol forming matrix.

14. An aerosol generation system comprising an aerosol generation article according to any of the preceding claims and an aerosol generation apparatus configured to receive the aerosol generation article.

15. The aerosol generation system of claim 14, wherein the aerosol generation apparatus includes a heater and a tensioning mechanism for applying tension to the aerosol forming matrix of the aerosol forming article, such that the aerosol forming matrix can be deployed from the aerosol forming article for use.

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