Aerosol-generating article having an asymmetric outer shape

Abstract

An aerosol-generating system is provided comprising an aerosol-generating article and an aerosol-generating device configured to receive the aerosol-generating article to generate an aerosol. The aerosol-generating article has a length extending in an x-direction between a distal end and a proximal end, a width extending in a y-direction between a left side and a right side, and a thickness extending in a z-direction between an upper side and a lower side. The length and the width are greater in magnitude than the thickness. The aerosol-generating device comprises an article-receiving cavity for receiving the aerosol-generating article for use. The article is asymmetrically shaped such that the distal end of the article is operatively engageable with the article-receiving cavity while the proximal end is not operatively engageable with the article-receiving cavity.

Description

Technical Field

[0001] This disclosure relates to aerosol generating articles and aerosol generating systems including aerosol generating articles and aerosol generating apparatus. Background Technology

[0002] Typical aerosol-generating articles can resemble regular cigarettes. For example, such an aerosol-generating article can be substantially cylindrical and includes an aerosol-forming matrix and other components (such as mouthpiece filter elements and cooling elements), all arranged together in a strip and wrapped in cigarette paper. The dimensions of a typical aerosol-generating article are generally similar to those of a regular cigarette.

[0003] However, a significant portion of the aerosol-forming matrix in these cylindrical aerosol-generating articles may not be adequately heated to form an aerosol during use. This is undesirable because the insufficiently heated portions of the aerosol-forming matrix affect the manufacturing and transportation costs of the aerosol-generating articles, but not the aerosol delivered to the end user. This is likely to occur regardless of how the aerosol-forming matrix is ​​heated, whether using a resistance heater or an induction heater, and whether it is heated internally or externally. Furthermore, the components of these cylindrical aerosol-generating articles typically need to have the same or very similar outer diameters so that they can be assembled together, accurately positioned coaxially, and wrapped in cigarette paper. This can lead to increased manufacturing costs and complexity. Summary of the Invention

[0004] Relatively "thin" aerosol generating articles can offer advantages over conventional aerosol generating articles. The object of this disclosure is to provide an improved aerosol generating article in which a larger portion of the aerosol-forming matrix of the aerosol generating article is sufficiently heated during use to form an aerosol. Another object of this disclosure is to provide an aerosol generating article that can be manufactured relatively efficiently and inexpensively. A further object of this disclosure is to provide an aerosol generating article optimized for use with an aerosol generating apparatus.

[0005] According to this disclosure, an aerosol generating article for use with an aerosol generating apparatus to generate aerosols can be provided. The aerosol generating article has a length extending in the x-direction between a distal and proximal end. The aerosol generating article has a width extending in the y-direction between a left and right side. The aerosol generating article has a thickness extending in the z-direction between an upper and lower side. The length and width of the aerosol generating article may be greater than the thickness. The aerosol generating article may include an upper surface. The aerosol generating article may include a lower surface. The aerosol generating article may include a matrix cavity located between the upper and lower surfaces. The matrix cavity may extend longitudinally within the article. The midpoint of the matrix cavity may be positioned closer to the distal end of the article than to the proximal end. The volume of the matrix cavity may be between 150 cubic millimeters and 400 cubic millimeters.

[0006] In a preferred embodiment, an aerosol generating article for use with an aerosol generating apparatus to generate aerosols can be provided. The aerosol generating article has a length extending in the x-direction between a distal and proximal end, a width extending in the y-direction between a left and right side, and a thickness extending in the z-direction between an upper and lower side, wherein the length and width are greater than the thickness. The aerosol generating article includes: an upper surface; a lower surface; and a matrix cavity located between the upper and lower surfaces, wherein the matrix cavity extends longitudinally within the article, and wherein the midpoint of the matrix cavity is positioned closer to the distal end of the article than to the proximal end of the article, wherein the volume of the matrix cavity is between 150 cubic millimeters and 400 cubic millimeters.

[0007] According to this disclosure, an aerosol generation system can be provided, the aerosol generation system including an aerosol generation article and an aerosol generation device configured to receive the aerosol generation article to generate an aerosol. The aerosol generation article has a length extending in the x-direction between a distal and proximal end. The aerosol generation article has a width extending in the y-direction between a left and right side. The aerosol generation article has a thickness extending in the z-direction between an upper and lower side. The length and width may be greater than the thickness in magnitude.

[0008] The aerosol generating apparatus may have a product receiving cavity for receiving aerosol-generated articles for use. The aerosol-generated articles may be asymmetrically shaped such that the distal end of the article can be operatively engaged with the product receiving cavity, while the proximal end cannot be operatively engaged with the product receiving cavity.

[0009] In a preferred embodiment, an aerosol generation system may be provided, comprising an aerosol generation article and an aerosol generation apparatus configured to receive the aerosol generation article to generate an aerosol. The aerosol generation article has a length extending in the x-direction between a distal and proximal end, a width extending in the y-direction between a left and right side, and a thickness extending in the z-direction between an upper and lower side, wherein the length and width are greater than the thickness. The aerosol generation apparatus has an article receiving cavity for receiving the aerosol generation article for use, wherein the article is asymmetrically shaped such that the distal end of the article can be operatively engaged with the article receiving cavity, while the proximal end cannot be operatively engaged with the article receiving cavity.

[0010] According to this disclosure, an aerosol generating article for use with an aerosol generating apparatus to generate aerosols can be provided. The aerosol generating article has a length extending in the x-direction between a distal and proximal end. The aerosol generating article has a width extending in the y-direction between a left and right side. The aerosol generating article has a thickness extending in the z-direction between a top and bottom side. The length and width of the article may be greater than the thickness of the article. The aerosol generating article may include a top surface. The aerosol generating article may include a bottom surface. The aerosol generating article may include a matrix cavity located between the top and bottom surfaces. A first airflow passage may extend between the distal end of the article and the cavity. A second airflow passage may extend between the cavity and the proximal end of the article. The length of the second airflow passage may be greater than the length of the first airflow passage. The minimum cross-sectional area of ​​the first airflow passage (in the yz plane) may be smaller than the minimum cross-sectional area of ​​the second airflow passage (in the yz plane).

[0011] In a preferred embodiment, an aerosol generating article for use with an aerosol generating apparatus to generate aerosols can be provided. The aerosol generating article has a length extending in the x-direction between a distal and proximal end, a width extending in the y-direction between a left and right side, and a thickness extending in the z-direction between an upper and lower side, wherein the length and width of the article are substantially greater than the thickness of the article. The aerosol generating article includes an upper surface; a lower surface; and a matrix cavity located between the upper and lower surfaces. A first airflow passage extends between the distal end of the article and the cavity, and a second airflow passage extends between the cavity and the proximal end of the article. The length of the second airflow passage is greater than the length of the first airflow passage, and the minimum cross-sectional area of ​​the first airflow passage (in the yz plane) is smaller than the minimum cross-sectional area of ​​the second airflow passage (in the yz plane).

[0012] The aerosol-generating article according to this disclosure may include a first planar outer surface and a second planar outer surface. The aerosol-generating article according to this disclosure may be referred to as a planar article and may be relatively "thin". The thickness of the article may be significantly less than the length or width of the article.

[0013] Advantageously, such articles can allow good contact with external heaters of the aerosol generating apparatus, particularly planar external heaters, thereby providing optimal heating of the aerosol generating matrix.

[0014] Advantageously, such articles can provide a large surface area for heating by an external heater of the aerosol generating apparatus, thereby allowing the aerosol generating matrix to be rapidly heated to a temperature sufficient to generate aerosols.

[0015] Advantageously, certain examples of the aerosol-generating articles of this disclosure can be manufactured by laminating sheet materials, which can be achieved through a continuous manufacturing process, thereby producing aerosol-generating articles that are relatively easy and inexpensive to manufacture.

[0016] The matrix cavity can be asymmetrically positioned within the article. The cavity may include a distal end and a proximal end. The cavity may include a midpoint located halfway between the distal and proximal ends. The matrix cavity can be asymmetrically positioned relative to the x-direction of the article, such that the midpoint is positioned closer to the distal end of the article than to the proximal end. The midpoint of the matrix cavity is the midpoint of the cavity relative to both its length and width.

[0017] Therefore, the matrix cavity can be positioned closer to the distal end of the article than to the proximal end. If the distal end of the article is inserted into the article receiving cavity of the aerosol generating device, the entire matrix cavity is easier to align with the heater and therefore easier to be heated compared to the case where the cavity is positioned symmetrically with respect to the length of the article.

[0018] The distance between the proximal end of the matrix cavity and the proximal end of the article can be greater than 10 mm, for example greater than 12 mm, for example greater than 15 mm, preferably between 11 mm and 16 mm. The distance between the distal end of the matrix cavity and the distal end of the article can be less than 4 mm, for example less than 3 mm, for example less than 2 mm, preferably between 4 mm and 2 mm.

[0019] Advantageously, the asymmetrical location of the cavity facilitates handling of the aerosol-generated article during or after heating. This is because the asymmetrical location of the cavity extends the distance from the proximal end of the aerosol-generated article to the heated portion of the article. Therefore, a larger portion of the aerosol-generated article can be easily grasped during or after heating. In particular, this facilitates removal of the aerosol-generated article after use. Furthermore, the proximal end of the article is less likely to be heated to high temperatures due to its distance from the matrix cavity, meaning that the proximal end of the article can be handled more comfortably immediately after use.

[0020] Advantageously, the asymmetrical location of the cavity (where the cavity midpoint is positioned closer to the distal end of the aerosol-generating article) allows the aerosol-generating apparatus configured to receive the article to have at least one heating element with a reduced length, compared to the case where the cavity is centrally located within the article. This is because the smaller distance between the proximal end of the cavity and the distal end of the aerosol-generating article compared to the case where the cavity is centrally located allows the heating element with the reduced length to still heat the entire length of the cavity. This improves the efficiency of the aerosol-generating apparatus because the smaller heating element can be used to heat the aerosol-generating matrix within the cavity of the aerosol-generating article.

[0021] The volume of the stromal cavity can be between 150 cubic millimeters and 400 cubic millimeters, for example, between 200 cubic millimeters and 380 cubic millimeters, for example, between 220 cubic millimeters and 370 cubic millimeters, for example, between 250 cubic millimeters and 350 cubic millimeters. The length of the stromal cavity can be between 10 mm and 20 mm, for example, between 12 mm and 15 mm, for example, approximately 12 mm, approximately 13 mm, approximately 14 mm, or approximately 15 mm. The maximum width of the stromal cavity can be between 6 mm and 10 mm, for example, between 7 mm and 8 mm, for example, approximately 7 mm or approximately 8 mm. The average width of the stromal cavity can be between 6 mm and 10 mm, for example, between 7 mm and 8 mm, for example, approximately 7 mm or approximately 8 mm. The thickness of the stromal cavity can be between 2.5 mm and 3.5 mm, for example, between 2.8 mm and 3.2 mm, for example, approximately 2.0 mm, approximately 3 mm, or approximately 3.1 mm.

[0022] Advantageously, the cavity size can provide a large cavity relative to the size of the aerosol-generated article without compromising the structural integrity of the aerosol-generated article.

[0023] The width of the distal end of the stromal cavity may be smaller than the width of the proximal end. Alternatively, the width of the distal end of the stromal cavity may be greater than the width of the proximal end. The stromal cavity may include rounded corners. The radius of the rounded corners may be between 0.5 mm and 2 mm, for example, 1.5 mm.

[0024] The aerosol-generating article may include a frame positioned between an upper surface and a lower surface. The frame may have an inner surface extending in the z-direction or lateral direction between the upper and lower surfaces. The frame may have an outer surface extending in the z-direction or lateral direction between the upper and lower surfaces. The frame may include a peripheral wall defining or surrounding a matrix cavity. The peripheral wall may be formed by the inner surface and the outer surface of the frame. The inner surface of the frame may define an outer wall of the cavity. The outer surface of the frame may at least partially define one or more outer walls of the aerosol-generating article.

[0025] The frame may have a thickness greater than or equal to 80% of the thickness of the aerosol-generating article. The frame may also have a thickness between 80% and 95% of the thickness of the aerosol-generating article. For example, the frame may have a thickness between 1 mm and 4 mm, such as between 2 mm and 3 mm.

[0026] The distance between the sidewall of the matrix cavity, such as the left or right sidewall, and the side surface of the article, such as the left or right side surface, can be less than 2 mm, such as less than 1.5 mm, such as less than 1 mm, preferably between 0.5 mm and 1.5 mm.

[0027] Advantageously, the distance between the sidewall of the matrix cavity and the side surface of the article is small without compromising the structural integrity of the article. Therefore, the aerosol-generated article can have a thin peripheral wall surrounding the cavity. This allows for a larger cavity relative to the size of the aerosol-generated article without compromising its structural integrity.

[0028] The aerosol-generating article may include a first airflow passage and a second airflow passage. The first airflow passage may extend between the distal end of the article and the matrix cavity. The second airflow passage may extend between the matrix cavity and the proximal end of the article. The first airflow passage may be an air inlet, and the second airflow passage may be an air outlet. Alternatively, the first airflow passage may be an air outlet, and the second airflow passage may be an air inlet.

[0029] The lengths of the first and second airflow passages can extend along the x-axis of the aerosol-generating article. The widths of the first and second airflow passages can extend along the y-axis of the aerosol-generating article. The thicknesses of the first and second airflow passages can extend along the z-axis of the aerosol-generating article.

[0030] The length of the second airflow passage can be greater than the length of the first airflow passage. For example, the length of the second airflow passage can be at least twice the length of the first airflow passage, such as at least three, four, or five times the length of the first airflow passage.

[0031] The length of the first airflow passage can be between 1.5 mm and 6 mm, for example, between 2 mm and 4 mm. The average width of the first airflow passage can be between 2 mm and 6 mm, for example, between 3 mm and 5 mm. The minimum width of the first airflow passage can be between 2 mm and 6 mm, for example, between 3 mm and 5 mm. The average thickness of the first airflow passage can be between 0.75 mm and 2.5 mm, for example, between 1 mm and 2 mm. The minimum thickness of the first airflow passage can be between 0.75 mm and 2.5 mm, for example, between 1 mm and 2 mm.

[0032] The length of the second airflow passage can be between 10 mm and 20 mm, for example, between 11 mm and 16 mm. The average width of the second airflow passage can be between 2 mm and 6 mm, for example, between 3 mm and 5 mm. The minimum width of the second airflow passage can be between 2 mm and 6 mm, for example, between 3 mm and 5 mm. The average thickness of the second airflow passage can be between 0.75 mm and 2.5 mm, for example, between 1 mm and 2 mm. The minimum thickness of the second airflow passage can be between 0.75 mm and 2.5 mm, for example, between 1 mm and 2 mm. The first airflow passage can be an air inlet. The second airflow passage can be an air outlet. Alternatively, the first airflow passage can be an air outlet, and the second airflow passage can be an air inlet.

[0033] Aerosol-generating articles may include an air inlet and an air outlet. The air inlet may extend between the distal end of the article and the matrix cavity. The air outlet may extend between the matrix cavity and the proximal end of the article. For example, the air inlet may be a first airflow passage, and the airflow outlet may be a second airflow passage.

[0034] The lengths of the air outlet and air inlet can be extended along the x-axis of the aerosol-generating article. The widths of the air outlet and air inlet can be extended along the y-axis of the aerosol-generating article. The thicknesses of the air outlet and air inlet can be extended along the z-axis of the aerosol-generating article.

[0035] For example, the length of the air inlet can be between 1.5mm and 6mm, for example, between 2mm and 4mm. For example, the average width of the air inlet can be between 2mm and 6mm, for example, between 3mm and 5mm. For example, the minimum width of the air inlet can be between 2mm and 6mm, for example, between 3mm and 5mm. For example, the average thickness of the air inlet can be between 0.75mm and 2.5mm, for example, between 1mm and 2mm. For example, the minimum thickness of the air inlet can be between 0.75mm and 2.5mm, for example, between 1mm and 2mm. The volume of the air inlet can be between 6 cubic millimeters and 40 cubic millimeters.

[0036] The length of the air outlet can be between 10mm and 20mm, for example, between 11mm and 16mm. The average width of the air outlet can be between 2mm and 6mm, for example, between 3mm and 5mm. The minimum width of the air outlet can be between 2mm and 6mm, for example, between 3mm and 5mm. The average thickness of the air outlet can be between 0.75mm and 2.5mm, for example, between 1mm and 2mm. The minimum thickness of the air outlet can be between 0.75mm and 2.5mm, for example, between 1mm and 2mm. The volume of the air outlet can be between 33 cubic millimeters and 160 cubic millimeters.

[0037] The length of the air outlet is preferably greater than the length of the air inlet. The length of the air outlet may be at least twice the length of the air inlet, for example, at least three, four, or five times the length of the air inlet.

[0038] Advantageously, a longer air outlet allows for more cooling of the aerosol before it enters the user's inlet. This is because a longer air outlet increases the surface area of ​​the air outlet (through which heat can dissipate) and prolongs the time it takes for heat to dissipate from the aerosol between leaving the matrix cavity and entering the user's inlet.

[0039] Aerosol formation by heating an aerosol matrix allows for the generation of moisture and slurry. This moisture and slurry can then be drawn towards the user during the use of the product. Providing a relatively long air outlet channel between the matrix cavity and the user allows some of this moisture and slurry to be retained by the walls of the air outlet and thus not transferred to the user.

[0040] The average width of the air outlet can be greater than the average width of the air inlet. The minimum width of the air outlet can be greater than the minimum width of the air inlet. The maximum width of the air outlet can be greater than the maximum width of the air inlet. The average thickness of the air outlet can be greater than the average thickness of the air inlet. The minimum thickness of the air outlet can be greater than the minimum thickness of the air inlet. The maximum thickness of the air outlet can be greater than the maximum thickness of the air inlet. Therefore, the average cross-sectional area of ​​the air inlet can be less than the average cross-sectional area of ​​the air outlet.

[0041] Advantageously, a smaller average air inlet cross-sectional area allows for reduced leakage of the aerosol-generating matrix from the matrix cavity to the inner surface of the air inlet. Although air is drawn into the inlet and exits through the outlet, there is still a possibility of moisture and slurry leaking into the device from the air inlet during use. Therefore, a smaller average air inlet cross-sectional area can help prevent unwanted leakage through the air inlet.

[0042] An air inlet may have a distal end located at the distal end of the article of work and a proximal end located at the inlet of the cavity. The cross-sectional area of ​​the proximal end of the air inlet may be smaller than the cross-sectional area of ​​the distal end of the air inlet. In other words, the cross-sectional area of ​​the air inlet at the cavity may be smaller than that at the distal end of the article of work. The width of the proximal end of the air inlet may be smaller than the width of the distal end of the air inlet. Alternatively or additionally, the thickness of the proximal end of the air inlet may be smaller than the thickness of the distal end of the air inlet. The width of the air inlet may decrease between the distal end and the proximal end of the air inlet. The width of the air inlet may decrease continuously or linearly. The thickness of the air inlet may decrease between the distal end and the proximal end of the air inlet. The thickness of the air inlet may decrease continuously or linearly.

[0043] Alternatively, the cross-sectional area of ​​the proximal end of the air inlet can be larger than the cross-sectional area of ​​the distal end of the air inlet. In other words, the cross-sectional area of ​​the air inlet at the cavity can be larger than that at the distal end of the work-in-process. The width of the proximal end of the air inlet can be greater than the width of the distal end of the air inlet. Alternatively or additionally, the thickness of the proximal end of the air inlet can be greater than the thickness of the distal end of the air inlet. The width of the air inlet can increase between the distal and proximal ends of the air inlet. The width of the air inlet can increase continuously or linearly. The thickness of the air inlet can increase between the distal and proximal ends of the air inlet. The thickness of the air inlet can increase continuously or linearly.

[0044] An air outlet may have a proximal end located near the article of work and a distal end located at the outlet end of the cavity. The cross-sectional area of ​​the proximal end of the air outlet may be smaller than the cross-sectional area of ​​the distal end of the air outlet. In other words, the cross-sectional area of ​​the air outlet at the cavity may be larger than that near the article of work. The width of the proximal end of the air outlet may be smaller than the width of the distal end of the air outlet. The thickness of the proximal end of the air outlet may be smaller than the thickness of the distal end of the air outlet. The width of the air outlet may decrease between the distal and proximal ends of the air outlet. The width of the air outlet may decrease continuously or linearly. The thickness of the air outlet may decrease between the distal and proximal ends of the air outlet. The thickness of the air outlet may decrease continuously or linearly.

[0045] The cross-sectional area of ​​the proximal end of the air outlet can be larger than that of the distal end. In other words, the cross-sectional area of ​​the air outlet at the cavity can be smaller than that at the proximal end of the work-in-process. The width of the proximal end of the air outlet can be greater than that of the distal end. The thickness of the proximal end of the air outlet can be greater than that of the distal end. The width of the air outlet can increase between the distal and proximal ends. The width of the air outlet can increase continuously or linearly. The thickness of the air outlet can increase between the distal and proximal ends. The thickness of the air outlet can increase continuously or linearly.

[0046] The deviation of the volume-to-length ratio of the air outlet from the volume-to-length ratio of the air inlet can be within 20%, for example, within 10%, 5%, or 1%. The volume-to-length ratio of the air outlet can be the same as that of the air inlet. The deviation of the average cross-sectional area of ​​the air outlet from the average cross-sectional area of ​​the air inlet can be within 20%, for example, within 10%, 5%, or 1%. The average cross-sectional area of ​​the air outlet can be the same as that of the air inlet.

[0047] Alternatively, the average cross-sectional area of ​​the air outlet can be greater than the average cross-sectional area of ​​the air inlet. The deviation of the ratio of the air outlet volume to the average cross-sectional area from the ratio of the air inlet volume to the average cross-sectional area can be within 20%, for example within 10%, 5%, or 1%. The ratio of the air outlet volume to the average cross-sectional area can be the same as the ratio of the air inlet volume to the average cross-sectional area.

[0048] The external shape of an aerosol-generated article can be asymmetrical. The external shape of the article can be asymmetrical in the x-direction. For example, the distal portion of the article can be shaped differently from the proximal portion. The distal portion of the article can be tapered. The distal portion of the article can be tapered in its width dimension. For example, the minimum width in the proximal portion of the article can be greater than the minimum width in the distal portion.

[0049] The width of the product taken in the y-axis at a point 3mm from the far end of the product can be smaller than the width taken in the y-axis at a point 3mm from the near end of the product, for example, between 1% and 15% smaller, or between 2% and 10% smaller.

[0050] Advantageously, a deviation of the width at a point 3 mm from the distal end of the aerosol-generating article relative to the width at a point 3 mm from the proximal end of the aerosol-generating article within 15% allows for easier manufacture of the aerosol-generating article. Therefore, the side of the article can taper slightly towards the distal end. By utilizing the slight taper of the distal portion of the article to provide asymmetry, the volume of the matrix cavity located in the distal portion of the article is unlikely to be significantly compromised. Thus, the loading of the aerosol-generating matrix can be maximized while still providing unidirectional insertion of the article into the device. Furthermore, if the width of the article at the distal end is not less than, for example, 15% of the width of the article at the proximal end, the ability to manufacture the article in a cost- and material-efficient manner can be optimized.

[0051] The external shape of the article can be mechanically configured such that the distal end of the article can be inserted into the aerosol generating device, while the proximal end cannot. Advantageously, this facilitates the correct orientation of the article into the aerosol generating device. The aerosol generating article may include a left side and a right side. A cavity may be located between the left and right side. The article may include a proximal surface and a distal surface, with the cavity located between the proximal and distal surfaces.

[0052] The aerosol-generating article may include a first distal corner and a second distal corner. The first distal corner and the second distal corner may be defined between the distal surface and the left and right surfaces, respectively. The first distal corner and the second distal corner may be rounded corners. The aerosol-generating article may include a first proximal corner and a second proximal corner. The first proximal corner and the second proximal corner may be defined between the proximal surface and the left and right surfaces, respectively. The first proximal corner and the second proximal corner may be rounded corners. The first distal corner and the second distal corner may have a smaller radius than the first proximal corner and the second proximal corner. The first distal corner and the second distal corner may have a radius between 0.5 mm and 2 mm, for example, about 1 mm. The first proximal corner and the second proximal corner may have a radius between 1 mm and 3 mm, for example, about 2 mm. The first distal corner and the second distal corner may have a smaller radius than the first proximal corner and the second proximal corner. Therefore, the proximal surface may be wider than the distal surface. This can advantageously prevent users from inserting the proximal end of the product into the aerosol generating device first.

[0053] Air can flow into the aerosol-generating article through the distal surface, through the matrix cavity, and out of the article through the proximal surface. For example, air can flow through the matrix cavity through an inlet defined in the distal surface and exit through an outlet defined to pass through the proximal surface.

[0054] The aerosol generating article may include one or more aerosol generating matrices. At least one of the one or more aerosol generating matrices may be positioned within a cavity. The aerosol generating matrix positioned within the cavity may include tobacco shredded filler. Alternatively or additionally, the aerosol generating matrix positioned within the cavity may be in the form of a plurality of free-flowing beads of aerosol forming material, such as a plurality of discrete free-flowing beads with an average bead diameter between 0.1 mm and 4 mm, preferably between 1 mm and 2 mm, for example between 1.2 mm and 1.7 mm.

[0055] The term "bead" refers to discrete solid particles formed from an aerosol-generating matrix. Beads can be spherical, typically rounded. Spherical or rounded beads have a low contact area with other beads, and multiple such beads can have good flowability. This means that a given mass or volume of such beads can flow freely. The ability of multiple beads to flow or be dumped can be very advantageous in providing a consistent dosage of the matrix during manufacturing. Other terms may be used to define the matrix, such as "particle".

[0056] Compared to other aerosol-forming matrices such as fine powders or filament fillers, beads are easier to handle. Beads flow easily and can therefore reliably and consistently fill the cavity of the aerosol-generated article during manufacturing. In particular, filament fillers cannot be reliably and repeatedly poured into the article cavity. This allows for a consistent and reproducible amount of aerosol-forming matrix to be loaded into each article during manufacturing. Beads can also be handled cleaner than powders and filament fillers, which can lead to dust in the plant and leakage from the aerosol-generated article during transport or use. By selecting beads with appropriate bead size and particle size distribution, airflow through the cavity of the aerosol-generated article can be controlled more reproducibly than with filament filler matrices. It should be noted that the multiple beads mentioned herein are multiple discrete beads, i.e., beads are not bound together with each other using a binder or matrix phase.

[0057] When the particle is not perfectly spherical, but the diameter of the particle is mentioned, the term "diameter" can refer to the maximum size of the particle. Alternatively, the term "diameter" can refer to the diameter of a perfectly spherical particle having the same volume as an imperfectly spherical particle.

[0058] As used herein, the term "average particle size" can refer to the index average particle size. Other methods for determining the average particle size are known. Therefore, the average particle size can be, for example, the volume average particle size.

[0059] Unless otherwise stated, the value given for average particle size in this specification refers to "number-average particle size". Specifically, "number-average particle size" is calculated as the sum of the diameters of the particles in a group divided by the number of particles in the group. Mathematically, this can be expressed as:

[0060]

[0061] In the above equation, N is the total number of particles, and It is the diameter of the nth particle.

[0062] Each of the multiple beads can be arranged according to the largest size (d) max ) and minimum size (d min The bead size is defined as follows: (The text abruptly ends here, so the translation stops as well.) max Preferably, the multiple beads have an average diameter (d) greater than 0.5 mm, for example, greater than 0.75 mm. min The bead size is chosen such that the beads flow easily and the volume of the beads is not so large that volatile components cannot be substantially completely released from each bead during a short duration of heating. The beads can be substantially spherical. The beads can be non-spherical, but in this case, they preferably have a low aspect ratio, such as oval, so that the beads still flow easily.

[0063] The aerosol generating matrix may contain aerosol generating materials. These aerosol generating materials may be in the form of shredded aerosol generating materials. Shredded aerosol generating materials include one or more of the following: strips and strands of aerosol generating materials, such as strips and strands of tobacco or homogenized tobacco materials.

[0064] The aerosol-generating matrix positioned within the cavity can have a mass between 50 mg and 500 mg. For example, the aerosol-generating matrix positioned within the cavity can have a mass between 100 mg and 350 mg, such as between 130 mg and 230 mg.

[0065] The length of the article can be greater than or equal to the width of the article. The width of the article can be at least twice the thickness of the article, for example at least three times the thickness, for example at least 3.5 times the thickness, or at least four times the thickness. Therefore, the thickness of the aerosol-generating article can be less than 50% of both the length and width of the aerosol-generating article. Advantageously, this increases the heating surface area of ​​the aerosol-generating article in the xy plane, which can allow for a more uniform heat distribution through the article.

[0066] The length of the product can be between 25mm and 35mm, for example, between 29mm and 31mm, or approximately 30mm. The width of the product can be between 8mm and 15mm, for example, between 10mm and 12mm, or approximately 11mm. The thickness of the product can be between 2.5mm and 3.5mm, for example, between 2.9mm and 3.3mm, or approximately 3.1mm, 3.2mm, or 3.3mm.

[0067] According to this disclosure, an aerosol generation system may be provided, comprising an aerosol generation article as described above and an aerosol generation apparatus configured to receive the aerosol generation article to generate an aerosol. The aerosol generation apparatus includes an article receiving cavity. The aerosol generation article may be asymmetrically shaped such that a distal end of the article can be operatively engaged with the article receiving cavity, while a proximal end cannot be operatively engaged with the article receiving cavity. The width of the distal portion of the article may be smaller than the width of the proximal portion of the article. The article receiving cavity may be sized to receive the article when the distal end of the article is inserted, but not when the proximal end of the article is inserted. The internal shape of the article receiving cavity may be configured to match the external shape of the proximal portion of the aerosol generation article when the article is operatively engaged with the article receiving cavity. The article may have rounded distal corners, and the article receiving cavity may include a distal end having rounded corners to engage with the distal end of the aerosol generation article.

[0068] As used herein, the term "aerosol-generating article" may refer to an article that can generate or release aerosols.

[0069] 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. The aerosol forming matrix may contain aerosol forming materials. The aerosol forming matrix may be adsorbed, coated, impregnated, or otherwise loaded onto a carrier or support.

[0070] 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.

[0071] As used herein, the term "aerosol generation system" refers to a combination of an aerosol generation apparatus and one or more aerosol forming articles for use with the apparatus. An aerosol generation system may include additional components, such as a charging unit for recharging an onboard power supply in an electrically operated or electrosol generation apparatus.

[0072] 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.

[0073] As used herein with reference to this invention, the term "nicotine" is used to describe nicotine, nicotine base, or nicotine salt.

[0074] 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 parts of aerosol-generating articles.

[0075] As used herein, the term "longitudinal" refers to the direction corresponding to the main longitudinal axis of the aerosol-generating article, which extends between the upstream and downstream ends of the aerosol-generating article. During use, air can be drawn through the aerosol-generating article in the longitudinal direction.

[0076] As used herein, the term "sheet" refers to a layered element whose width and length are significantly greater than its thickness. The width of the sheet may be greater than 10 mm, preferably greater than 20 mm or 30 mm. In some embodiments, the material sheet used to form the aerosol-forming matrix as described herein may have a thickness between 10 μm and about 1000 μm, for example between 10 μm and about 300 μm.

[0077] As used herein, the term "homogenized tobacco material" includes any tobacco material formed by the agglomeration of particulate tobacco material. Homogenized tobacco material sheets or webs are formed by agglomerating particulate tobacco obtained by grinding or otherwise pulverizing one or both of tobacco leaves and tobacco stems. Additionally, homogenized tobacco material may include small amounts of one or more of tobacco dust, tobacco dregs, and other particulate tobacco byproducts formed during tobacco processing, handling, and transportation. Homogenized tobacco material sheets can be produced by casting, extrusion, papermaking processes, or any other suitable processes known in the art.

[0078] The term "cast leaf" is used herein to refer to a product manufactured by a casting process, which is based on casting a slurry comprising plant particles (e.g., clove particles or a mixture of tobacco particles and clove particles) and a binder (e.g., guar gum) onto a support surface (such as a belt conveyor), drying the slurry, and removing the dried sheet from the support surface. Examples of casting or the casting leaf process are described, for example, in US-A-5,724,998 for the manufacture of cast leaf tobacco. In the casting leaf process, granular plant material is produced by grinding, milling, or pulverizing portions of a plant. Particles produced from one or more plants are mixed with a liquid component (typically water) to form a slurry. Other components in the slurry may include fibers, binders, and aerosol-forming agents. The granular plant material may agglomerate in the presence of a binder. The slurry is cast onto a support surface and dried into a homogenized sheet of plant material. Preferably, the homogenized plant material for articles according to the invention can be produced by casting. Such homogenized plant material may comprise agglomerated granular plant material.

[0079] As used herein, the term "particle size" can refer to a single dimension and can be used to characterize the size of a given particle. A dimension can be the diameter of a spherical particle occupying the same volume as a given particle. All particle sizes and particle size distributions described herein can be obtained using standard laser diffraction techniques. Commercially available sensors, such as the Sympatec HELOS laser diffraction sensor, can be used to obtain the particle sizes and particle size distributions described herein.

[0080] As used herein, unless otherwise specified, the term "density" may refer to true density. Therefore, unless otherwise specified, the density of a powder or particles may refer to the true density of the powder or particles (rather than the bulk density, which can vary considerably depending on how the powder or particles are handled). True density can be measured using many standard methods, often based on Archimedes' principle. The most widely used method for measuring the true density of a powder involves placing the powder inside a container of known volume (a specific gravity bottle) and weighing it. The specific gravity bottle is then filled with a fluid of known density in which the powder is insoluble. The volume of the powder is determined by the difference between the volume shown in the specific gravity bottle and the volume of the added liquid (i.e., the volume of displaced air).

[0081] 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.

[0082] Exi. An aerosol generating article for use with an aerosol generating apparatus to generate an aerosol, the aerosol generating article having a length extending in the x-direction between a distal and proximal end, a width extending in the y-direction between a left and right side, and a thickness extending in the z-direction between an upper and lower side, wherein the length and the width are substantially greater than the thickness, the aerosol generating article comprising a matrix cavity.

[0083] The matrix cavity extends longitudinally within the article.

[0084] Exii. An aerosol generating article for use with an aerosol generating apparatus to generate an aerosol, such as the aerosol generating article according to Exi, the aerosol generating article comprising: a first outer surface and a second outer surface, and a cavity located between the first outer surface and the second outer surface.

[0085] Exiii. An aerosol generating article for use with an aerosol generating apparatus to generate aerosols, such as the aerosol generating article according to Exi or Exii, the aerosol generating article comprising one or more aerosol forming matrices located in a matrix cavity, the aerosol generating article comprising a first planar outer surface and a second planar outer surface.

[0086] Exiv. An aerosol generating article for use with an aerosol generating apparatus to generate an aerosol, such as an aerosol generating article according to any of the foregoing examples, the aerosol generating article having a base defined by an x-dimensional extending in the x-direction and a y-dimensional extending in the y-direction, and a height defined by a z-dimensional extending in the z-direction, the cavity being located within the article.

[0087] Exv. An aerosol generating article for use with an aerosol generating apparatus to generate an inhalable aerosol, such as an aerosol generating article according to any of the foregoing examples, the aerosol generating article comprising an upstream or distal end of an article and a downstream or proximal end of an article, wherein an article airflow path and an article length extend from the upstream / distal end of the article to the downstream / proximal end of the article.

[0088] Exvi. An aerosol generating article for use with an aerosol generating apparatus to generate an aerosol, such as an aerosol generating article according to any of the foregoing examples, the aerosol generating article comprising: a first planar outer surface; a second planar outer surface; a cavity; a frame positioned between the first planar outer surface and the second planar outer surface, the frame at least partially defining the cavity; one or more aerosol generating matrices; and an air inlet and an air outlet, an airflow passage extending through the cavity between the air inlet and the air outlet.

[0089] Exvii. An aerosol generating article for use with an aerosol generating apparatus to generate aerosols, such as an aerosol generating article according to any of the foregoing examples, the aerosol generating article having a length extending in the x-direction between a distal and proximal end, a width extending in the y-direction between a left and right side, and a thickness extending in the z-direction between an upper and lower side, wherein the length and the width are substantially greater than the thickness, the aerosol generating article comprising a matrix cavity.

[0090] The matrix cavity extends longitudinally within the article, and the midpoint of the matrix cavity is positioned closer to the distal end of the article than to the proximal end of the article.

[0091] Ex1. An aerosol generating article for use with an aerosol generating apparatus to generate an aerosol, such as an aerosol generating apparatus according to any of the foregoing examples, the aerosol generating article having a length extending in the x-direction between a distal and proximal end, a width extending in the y-direction between a left and right side, and a thickness extending in the z-direction between an upper and lower side, wherein the length and the width are substantially greater than the thickness, the aerosol generating article comprising:

[0092] upper surface;

[0093] The lower surface; and

[0094] The matrix cavity located between the upper surface and the lower surface

[0095] The matrix cavity extends longitudinally within the article, and the midpoint of the matrix cavity is positioned closer to the distal end of the article than to the proximal end of the article.

[0096] Ex2. An aerosol generating article for use with an aerosol generating apparatus to generate an aerosol, such as an aerosol generating apparatus according to any of the foregoing examples, the aerosol generating article having a length extending in the x-direction between a distal and proximal end, a width extending in the y-direction between a left and right side, and a thickness extending in the z-direction between an upper and lower side, the aerosol generating article comprising:

[0097] upper surface;

[0098] The lower surface; and

[0099] The matrix cavity located between the upper surface and the lower surface

[0100] The matrix cavity is asymmetrically positioned within the article.

[0101] Ex3. An aerosol generating article for use with an aerosol generating apparatus to generate an aerosol, such as an aerosol generating apparatus according to any of the foregoing examples, or the aerosol generating article having a length extending in the x-direction between a distal and proximal end, a width extending in the y-direction between a left and right side, and a thickness extending in the z-direction between an upper and lower side, the aerosol generating article comprising:

[0102] upper surface;

[0103] The lower surface; and

[0104] The matrix cavity located between the upper surface and the lower surface

[0105] The matrix cavity extends longitudinally in the x-direction between the distal and proximal ends of the matrix cavity within the article, with the midpoint of the matrix cavity located at the midpoint between the distal and proximal ends of the matrix cavity.

[0106] Furthermore, the matrix cavity is positioned asymmetrically relative to the article in the x-direction, such that the midpoint of the matrix cavity is positioned closer to the distal end of the article than to the proximal end of the article.

[0107] Ex3A. An aerosol generating article for use with an aerosol generating apparatus to generate an aerosol, such as an aerosol generating apparatus according to any of the foregoing examples, the aerosol generating article having a length extending in the x-direction between a distal and proximal end, a width extending in the y-direction between a left and right side, and a thickness extending in the z-direction between an upper and lower side, wherein the length and width of the article are substantially greater than the thickness of the article, the aerosol generating article comprising:

[0108] upper surface;

[0109] The lower surface; and

[0110] The matrix cavity located between the upper surface and the lower surface

[0111] The first airflow passage extends between the distal end of the article and the cavity, and the second airflow passage extends between the cavity and the proximal end of the article, wherein the length of the second airflow passage is greater than the length of the first airflow passage.

[0112] The minimum cross-sectional area of ​​the first airflow passage (i.e., in the yz plane) is smaller than the minimum cross-sectional area of ​​the second airflow passage (i.e., in the yz plane).

[0113] Ex4. An aerosol-generating article according to any of the foregoing examples, wherein the volume of the matrix cavity is between 150 cubic millimeters and 400 cubic millimeters, for example between 200 cubic millimeters and 380 cubic millimeters, for example between 220 cubic millimeters and 370 cubic millimeters, for example between 250 cubic millimeters and 350 cubic millimeters.

[0114] Ex5. An aerosol-generated article according to any of the foregoing examples, wherein the length of the matrix cavity is between 10 mm and 20 mm, for example between 12 mm and 15 mm, for example about 12 mm or about 13 mm or about 14 mm or about 15 mm.

[0115] Ex6. An aerosol-generated article according to any of the foregoing examples, wherein the maximum width of the matrix cavity is between 6 mm and 10 mm, for example between 7 mm and 8 mm, for example about 7 mm or about 8 mm.

[0116] Ex7. An aerosol-generated article according to any of the foregoing examples, wherein the average width of the matrix cavity is between 6 mm and 10 mm, for example between 7 mm and 8 mm, for example about 7 mm or about 8 mm.

[0117] Ex8. An aerosol-generated article according to any of the foregoing examples, wherein the thickness of the matrix cavity is between 2.5 mm and 3.5 mm, for example between 2.8 mm and 3.2 mm, for example about 2.0 mm, about 3 mm, or about 3.1 mm.

[0118] Ex9. An aerosol-generated article according to any of the foregoing examples, wherein the matrix cavity includes a proximal end and a distal end.

[0119] Ex10. An aerosol-generated article according to Ex9, wherein the width of the distal end of the matrix cavity is smaller than the width of the proximal end of the cavity.

[0120] Ex11. An aerosol-generated article according to Ex9, wherein the width of the distal end of the matrix cavity is greater than the width of the proximal end of the cavity.

[0121] Ex12. An aerosol-generated article according to any of the foregoing examples, the article comprising an upper surface, a lower surface, and a frame positioned between the upper surface and the lower surface.

[0122] Ex13. An aerosol-generated article according to Ex12, wherein the frame has an inner frame surface extending between the upper surface and the lower surface in the z-direction or the transverse direction.

[0123] Ex14. An aerosol-generated article according to Ex12 or 13, wherein the frame has an outer frame surface extending between the upper surface and the lower surface in the z-direction or the transverse direction.

[0124] Ex15. An aerosol-generating article according to any one of Examples 12 to 14, wherein the frame includes a peripheral wall defining or surrounding the matrix cavity.

[0125] Ex16. An aerosol-generating article according to any one of Examples 12 to 15, wherein the peripheral wall is formed by an inner surface of a frame and an outer surface of a frame, wherein the inner surface of the frame defines an outer wall of a cavity, and the outer surface of the frame at least partially defines one or more outer walls of the aerosol-generating article.

[0126] Ex17. An aerosol-generating article according to any one of Examples 12 to 16, wherein the frame has a thickness greater than or equal to 80% of the thickness of the aerosol-generating article.

[0127] Ex18. An aerosol-generating article according to any one of Examples 12 to 17, wherein the frame has a thickness between 80% and 95% of the thickness of the aerosol-generating article.

[0128] Ex19. An aerosol-generated article according to any one of Examples 12 to 18, wherein the frame has a thickness between 1 mm and 4 mm, for example between 2 mm and 3 mm.

[0129] Ex20. An aerosol-generated article according to any of the foregoing examples, wherein the distance between the proximal end of the matrix cavity and the proximal end of the article is greater than 10 mm, for example greater than 12 mm, for example greater than 15 mm, preferably between 11 mm and 16 mm.

[0130] Ex20A. An aerosol-generated article according to any of the foregoing examples, wherein the distance between the sidewall, such as the left or right sidewall, of the matrix cavity and the side surface, such as the left or right surface of the article is less than 2 mm, such as less than 1.5 mm, such as less than 1 mm, preferably between 0.5 mm and 1.5 mm.

[0131] Ex21. An aerosol-generated article according to any of the foregoing examples, wherein the distance between the distal end of the matrix cavity and the distal end of the article is less than 4 mm, for example less than 3 mm, for example less than 2 mm, preferably between 4 mm and 2 mm.

[0132] Ex21A. An aerosol-generated article according to any of the foregoing examples, wherein the article includes a first airflow passage and a second airflow passage, the first airflow passage extending between a distal end of the article and the matrix cavity, and the second airflow passage extending between the matrix cavity and a proximal end of the article.

[0133] Ex21B. An aerosol-generating article according to any of the foregoing examples, wherein the first airflow passage is an air inlet and the second airflow passage is an air outlet.

[0134] Ex21C. An aerosol-generating article according to any of the foregoing examples, wherein the first airflow passage is an air outlet and the second airflow passage is an air inlet.

[0135] Ex21D. An aerosol generating article according to any one of Ex21A to Ex21C, wherein the length of the second airflow passage is greater than the length of the first airflow passage, for example, wherein the length of the second airflow passage is at least twice the length of the first airflow passage, for example, at least three times, at least four times, or at least five times the length of the first airflow passage.

[0136] Ex21E. An aerosol-generating article according to any one of Examples Ex21A to Ex21D, wherein the length of the first airflow passage is between 1.5 mm and 6 mm, for example, between 2 mm and 4 mm.

[0137] Ex21F. An aerosol-generating article according to any one of Examples Ex21A to Ex21E, wherein the average width of the first airflow passage is between 2 mm and 6 mm, for example, between 3 mm and 5 mm.

[0138] Ex21G. An aerosol-generating article according to any one of Examples Ex21A to Ex21F, wherein the minimum width of the first airflow passage is between 2 mm and 6 mm, for example, between 3 mm and 5 mm.

[0139] Ex21H. An aerosol-generating article according to any one of Examples Ex21A to Ex21G, wherein the average thickness of the first airflow passage is between 0.75 mm and 2.5 mm, for example, between 1 mm and 2 mm.

[0140] Ex21I. An aerosol-generating article according to any one of Examples Ex21A to Ex21H, wherein the minimum thickness of the first airflow passage is between 0.75 mm and 2.5 mm, for example, between 1 mm and 2 mm.

[0141] Ex21J. An aerosol-generating article according to any one of Examples Ex21A to Ex21I, wherein the length of the second airflow passage is between 10 mm and 20 mm, for example between 11 mm and 16 mm.

[0142] Ex21K. An aerosol-generating article according to any one of Examples Ex21A to Ex21J, wherein the average width of the second airflow passage is between 2 mm and 6 mm, for example, between 3 mm and 5 mm.

[0143] Ex21L. An aerosol generating article according to any one of Examples Ex21A to Ex21K, wherein the minimum width of the second airflow passage intercepted in the y-axis of the aerosol generating article is between 2 mm and 6 mm, for example, between 3 mm and 5 mm.

[0144] Ex21M. An aerosol-generating article according to any one of Examples Ex21A to Ex21L, wherein the average thickness of the second airflow passage is between 0.75 mm and 2.5 mm, for example, between 1 mm and 2 mm.

[0145] Ex21J. An aerosol generating article according to any one of Examples Ex21A to Ex21I, wherein the minimum thickness of the second airflow passage intercepted in the z-axis of the aerosol generating article is between 0.75 mm and 2.5 mm, for example, between 1 mm and 2 mm.

[0146] Ex22. An aerosol-generating article according to any of the foregoing examples, wherein the article includes an air inlet and an air outlet, the air inlet extending between a distal end of the article and the matrix cavity, and the air outlet extending between the matrix cavity and a proximal end of the article, for example wherein the air inlet is the first airflow passage of Ex21A, and the airflow outlet is the second airflow passage of Ex21A.

[0147] Ex23. An aerosol generating article according to Ex22, wherein the length of the air outlet is greater than the length of the air inlet, for example, wherein the length of the air outlet and the length of the air inlet extend along the x-axis of the aerosol generating article.

[0148] Ex24. An aerosol-generating article according to Ex22 or Ex23, wherein the length of the air outlet is at least twice the length of the air inlet, for example, at least three, four, or five times the length of the air outlet.

[0149] Ex25. An aerosol-generating article according to any one of Examples Ex22 to Ex24, wherein the length of the air inlet is between 1.5 mm and 6 mm, for example, between 2 mm and 4 mm.

[0150] Ex26. An aerosol-generating article according to any one of Examples Ex22 to Ex25, wherein the average width of the air inlet is between 2 mm and 6 mm, for example between 3 mm and 5 mm, wherein the width of the air outlet and the width of the air inlet extend along the y-axis of the aerosol-generating article.

[0151] Ex26A. An aerosol-generating article according to any one of Examples Ex22 to Ex25, wherein the minimum width of the air inlet, taken along the y-axis of the aerosol-generating article, is between 2 mm and 6 mm, for example, between 3 mm and 5 mm.

[0152] Ex27. An aerosol generating article according to any one of Examples Ex22 to Ex26A, wherein the average thickness of the air inlet is between 0.75 mm and 2.5 mm, for example between 1 mm and 2 mm, wherein the thickness of the air outlet and the thickness of the air inlet extend along the z-axis of the aerosol generating article.

[0153] Ex27A. An aerosol-generating article according to any one of Examples Ex22 to Ex26A, wherein the minimum thickness of the air inlet, taken along the z-axis of the aerosol-generating article, is between 0.75 mm and 2.5 mm, for example, between 1 mm and 2 mm.

[0154] Ex28. An aerosol-generating article according to any one of Examples Ex22 to Ex27A, wherein the length of the air outlet is between 10 mm and 20 mm, for example between 11 mm and 16 mm.

[0155] Ex29. An aerosol-generating article according to any one of Examples Ex22 to Ex28, wherein the average width of the air outlet is between 2 mm and 6 mm, for example, between 3 mm and 5 mm.

[0156] Ex29A. An aerosol generating article according to any one of Examples Ex22 to Ex29, wherein the minimum width of the air outlet, taken along the y-axis of the aerosol generating article, is between 2 mm and 6 mm, for example, between 3 mm and 5 mm.

[0157] Ex30. An aerosol-generating article according to any one of Examples Ex22 to Ex29A, wherein the volume of the air outlet is between 33 cubic millimeters and 160 cubic millimeters.

[0158] Ex31. An aerosol-generating article according to any one of Examples Ex22 to Ex30, wherein the volume of the air inlet is between 6 cubic millimeters and 40 cubic millimeters.

[0159] Ex32. An aerosol-generating article according to any one of Examples Ex22 to Ex31, wherein the average thickness of the air outlet is between 0.75 mm and 2.5 mm, for example, between 1 mm and 2 mm.

[0160] Ex32A. An aerosol generating article according to any one of Examples Ex22 to Ex32, wherein the minimum thickness of the air outlet, taken along the z-axis of the aerosol generating article, is between 0.75 mm and 2.5 mm, for example, between 1 mm and 2 mm.

[0161] Ex33. An aerosol generating article according to any one of Examples Ex22 to Ex32A, wherein the average width of the air outlet is greater than the average width of the air inlet.

[0162] Ex33A. An aerosol generating article according to any one of Examples Ex22 to Ex33, wherein the minimum width of the air outlet is greater than the minimum width of the air inlet.

[0163] Ex34. An aerosol generating article according to any one of Examples Ex22 to Ex33A, wherein the maximum width of the air outlet is greater than the maximum width of the air inlet.

[0164] Ex35. An aerosol-generating article according to any one of Examples Ex22 to Ex34, wherein the average thickness of the air outlet is greater than the average thickness of the air inlet.

[0165] Ex35A. An aerosol-generating article according to any one of Examples Ex22 to Ex35, wherein the minimum thickness of the air outlet is greater than the minimum thickness of the air inlet.

[0166] Ex36. An aerosol-generating article according to any one of Examples Ex22 to Ex35A, wherein the maximum thickness of the air outlet is greater than the maximum thickness of the air inlet.

[0167] Ex37. An aerosol-generating article according to any one of Examples Ex22 to Ex36, wherein the air inlet has a distal end located at a distal end of the article and a proximal end located at an inlet of the cavity.

[0168] Ex37A. An aerosol-generating article according to Ex37, wherein the cross-sectional area of ​​the proximal end of the air inlet is smaller than the cross-sectional area of ​​the distal end of the air inlet, that is, the cross-sectional area of ​​the air inlet is smaller at the cavity than at the distal end of the article.

[0169] Ex37B. An aerosol-generating article according to Ex37 or Ex37A, wherein the width of the proximal end of the air inlet is smaller than the width of the distal end of the air inlet.

[0170] Ex37C. An aerosol-generating article according to Ex37 or Ex37A, wherein the thickness of the proximal end of the air inlet is less than the thickness of the distal end of the air inlet.

[0171] Ex38. Aerosol-generating articles according to Ex37 to Ex37C, wherein the width of the air inlet increases between the distal end and the proximal end of the air inlet, for example, increasing continuously or linearly.

[0172] Ex39. Aerosol-generating articles according to Ex37 to Ex38, wherein the thickness of the air inlet increases between the distal end and the proximal end of the air inlet, for example, by a continuous or linear increase.

[0173] Ex40. An aerosol-generating article according to Ex37, wherein the cross-sectional area of ​​the proximal end of the air inlet is greater than the cross-sectional area of ​​the distal end of the air inlet, that is, the cross-sectional area of ​​the air inlet is larger at the cavity than at the distal end of the article.

[0174] Ex40A. An aerosol-generating article according to Ex37 or Ex40, wherein the width of the proximal end of the air inlet is greater than the width of the distal end of the air inlet.

[0175] Ex40B. An aerosol-generating article according to Ex37, Ex40 or Ex40A, wherein the thickness of the proximal end of the air inlet is greater than the thickness of the distal end of the air inlet.

[0176] Ex41. An aerosol-generating article according to Ex37, wherein the width of the air inlet decreases between the distal end and the proximal end of the air inlet, for example, decreasing continuously or linearly.

[0177] Ex42. An aerosol-generating article according to Ex37 or Ex41, wherein the thickness of the air inlet decreases between the distal end and the proximal end of the air inlet, for example, decreasing continuously or linearly.

[0178] Ex43. An aerosol generating article according to any one of Examples Ex22 to Ex42, wherein the air outlet has a proximal end located at a proximal end of the article and a distal end located at an outlet end of the cavity.

[0179] Ex44. An aerosol-generating article according to Ex43, wherein the cross-sectional area of ​​the proximal end of the air outlet is smaller than the cross-sectional area of ​​the distal end of the air outlet, that is, the cross-sectional area of ​​the air outlet is larger at the cavity than at the proximal end of the article.

[0180] Ex44B. An aerosol-generating article according to Ex43 or Ex44, wherein the width of the proximal end of the air outlet is smaller than the width of the distal end of the air outlet.

[0181] Ex44C. An aerosol generating article according to any one of Examples Ex43 to Ex44B, wherein the thickness of the proximal end of the air outlet is less than the thickness of the distal end of the air outlet.

[0182] Ex45. Aerosol generating articles according to Ex43 to Ex44C, wherein the width of the air outlet increases between the proximal end and the distal end of the air outlet, for example, by a continuous or linear increase.

[0183] Ex46. Aerosol-generating articles according to Ex43 to Ex45, wherein the thickness of the air outlet increases between the proximal end and the distal end of the air outlet, for example, by a continuous or linear increase.

[0184] Ex47. An aerosol-generating article according to Ex43, wherein the cross-sectional area of ​​the proximal end of the air outlet is greater than the cross-sectional area of ​​the distal end of the air outlet, that is, the cross-sectional area of ​​the air outlet is smaller at the cavity than at the proximal end of the article.

[0185] Ex47A. An aerosol-generating article according to Ex43 or Ex47, wherein the width of the proximal end of the air outlet is greater than the width of the distal end of the air outlet.

[0186] Ex47B. An aerosol-generating article according to Ex43, Ex47 or Ex47A, wherein the thickness of the proximal end of the air outlet is greater than the thickness of the distal end of the air outlet.

[0187] Ex48. An aerosol-generating article according to Ex43, wherein the width of the air outlet decreases between the proximal end and the distal end of the air outlet, for example, decreasing continuously or linearly.

[0188] Ex48A. An aerosol-generating article according to Ex43 or Ex48, wherein the thickness of the air outlet decreases between the proximal end and the distal end of the air outlet, for example, decreasing continuously or linearly.

[0189] Ex49. An aerosol generating article according to any one of Ex21A to Ex48A, wherein the deviation of the ratio of the volume to length of the air outlet relative to the ratio of the volume to length of the air inlet is within 20%, for example within 10%, 5%, or 1%.

[0190] Ex50. An aerosol generating article according to any one of Ex21A to Ex49, wherein the ratio of the volume to the length of the air outlet is the same as the ratio of the volume to the length of the air inlet.

[0191] Ex51. An aerosol generating article according to any one of Ex21A to Ex50, wherein the deviation of the average cross-sectional area of ​​the air outlet from the average cross-sectional area of ​​the air inlet is within 20%, for example within 10%, 5%, or 1%.

[0192] Ex52. An aerosol generating article according to any one of Ex21A to Ex51, wherein the average cross-sectional area of ​​the air outlet is the same as the average cross-sectional area of ​​the air inlet.

[0193] Ex53. An aerosol generating article according to any one of Ex21A to Ex52, wherein the average cross-sectional area of ​​the air outlet is greater than the average cross-sectional area of ​​the air inlet.

[0194] Ex54. An aerosol-generating article according to any one of Ex21A to Ex53, wherein the deviation of the ratio of the volume of the air outlet to the average cross-sectional area relative to the ratio of the volume of the air inlet to the average cross-sectional area is within 20%, for example within 10%, 5%, or 1%.

[0195] Ex55. An aerosol-generating article according to any one of Ex21A to Ex54, wherein the ratio of the volume of the air outlet to the average cross-sectional area is the same as the ratio of the volume of the air inlet to the average cross-sectional area.

[0196] Ex56. An aerosol-generated article according to any of the foregoing examples, wherein the external shape of the article is asymmetrical.

[0197] Ex57. An aerosol-generated article according to any of the foregoing examples, wherein the external shape of the article is asymmetrical in the x-direction, for example, wherein the distal portion of the article is shaped differently from the proximal portion of the article.

[0198] Ex58. An aerosol-generated article according to Ex57, wherein the distal portion of the article tapers, for example, in its width dimension, such that the minimum width in the proximal portion of the article is greater than the minimum width in the distal portion of the article.

[0199] Ex59. An aerosol-generated article according to Ex57 or Ex58, wherein the width of the article taken in the y-axis at a point 3 mm from the far end of the article is less than the width of the article taken in the y-axis at a point 3 mm from the near end of the article, for example, between 1% and 15%, or between 2% and 10%.

[0200] Ex60. An aerosol-generating article according to any of the foregoing examples, wherein the external shape of the article is mechanically configured such that the distal end of the article can be inserted into an aerosol-generating device, while the proximal end cannot be inserted into an aerosol-generating device.

[0201] Ex61. An aerosol-generated article according to any of the foregoing examples, wherein the article includes a left side and a right side, and the cavity is located between the left side and the right side.

[0202] Ex62. An aerosol-generated article according to any of the foregoing examples, wherein the article includes a proximal surface and a distal surface, and the cavity is located between the proximal surface and the distal surface.

[0203] Ex63. Aerosol-generated articles according to Ex61 and Ex62, wherein the first and second distal corners, respectively defined between the distal surface and the left and right surfaces, are rounded corners.

[0204] Ex64. Aerosol-generated articles according to Ex61 and Ex62, wherein the first proximal corner and the second proximal corner, respectively defined between the proximal surface and the left and right surfaces, are rounded corners.

[0205] Ex65. Aerosol-generated articles according to Ex63 and Ex64, wherein the first distal corner and the second distal corner have smaller radii than the first proximal corner and the second proximal corner.

[0206] Ex66. An aerosol-generated article according to any one of Ex63 to Ex65, wherein the first distal corner and the second distal corner have radii between 0.5 mm and 2 mm, for example about 1 mm.

[0207] Ex67. An aerosol-generated article according to any one of Ex63 to Ex66, wherein the first proximal corner and the second proximal corner have a radius between 1 mm and 3 mm, for example about 2 mm.

[0208] Ex68. An aerosol-generating article according to any of the foregoing examples includes one or more aerosol-generating matrices.

[0209] Ex69. An aerosol generating article according to Ex68, wherein at least one of the one or more aerosol generating matrices is positioned within the cavity.

[0210] Ex70. An aerosol-generating article according to Ex69, wherein the aerosol-generating matrix positioned within the cavity comprises tobacco shredded filler.

[0211] Ex71. An aerosol generating article according to Ex69, wherein the aerosol generating matrix positioned within the cavity is in the form of a plurality of free-flowing beads of aerosol forming material, the plurality of free-flowing beads being, for example, a plurality of discrete free-flowing beads with an average bead diameter between 0.1 mm and 4 mm, preferably between 1 mm and 2 mm, for example between 1.2 mm and 1.7 mm.

[0212] Ex72. An aerosol-generating article according to Ex69, wherein the aerosol-generating material is in the form of shredded aerosol-generating material.

[0213] Ex73. An aerosol-generating article according to Ex72, wherein the shredded aerosol-generating material comprises one or more of the following: strips and strands of aerosol-generating material, such as strips and strands of tobacco or homogenized tobacco material.

[0214] Ex74. An aerosol-generating article according to any of the foregoing examples, wherein the thickness of the aerosol-generating article is less than 50% of both the length and width of the aerosol-generating article.

[0215] Ex75. An aerosol-generating article according to any of the foregoing examples, wherein the aerosol-generating matrix positioned within the cavity has a mass between 50 mg and 500 mg.

[0216] Ex76. An aerosol-generating article according to any of the foregoing examples, wherein the aerosol-generating matrix positioned within the cavity has a mass between 100 mg and 350 mg, for example between 130 mg and 230 mg.

[0217] Ex77. An aerosol generating article for use with an aerosol generating apparatus to generate an aerosol, such as an aerosol generating article according to any of the foregoing examples, the aerosol generating article comprising: a first planar outer surface and a second planar outer surface, a left side surface and a right side surface, a proximal surface and a distal surface, and a matrix cavity located within the article, wherein a first distal corner and a second distal corner defined between the distal surface and the left side surface and between the distal surface and the right side surface, respectively, are rounded corners.

[0218] Ex78. An aerosol-generating article according to Ex77, wherein a first proximal corner and a second proximal corner, respectively defined between the proximal surface and the left side surface and between the proximal surface and the right side surface, are rounded corners.

[0219] Ex79. Aerosol-generated articles according to Ex77 and Ex78, wherein the first distal corner and the second distal corner have smaller radii than the first proximal corner and the second proximal corner.

[0220] Ex80. An aerosol-generated article according to any one of Ex77 to Ex79, wherein the first distal corner and the second distal corner have radii between 0.5 mm and 2 mm.

[0221] Ex81. An aerosol-generated article according to any one of Ex77 to Ex80, wherein the first proximal corner and the second proximal corner have radii between 1 mm and 3 mm.

[0222] Ex82. An aerosol-generating article according to any one of Ex77 to Ex81, wherein the proximal surface is wider than the distal surface.

[0223] Ex83. An aerosol-generated article according to any one of Ex77 to Ex82, wherein air flows into the article through the distal surface, for example through an inlet defined in the distal surface, flows through the matrix cavity, and flows out of the article through the proximal surface, for example through an outlet defined to pass through the proximal surface.

[0224] Ex83A. An aerosol-generated article according to any of the foregoing examples, wherein the length of the article is greater than or equal to the width of the article, and the width of the article is at least twice the thickness of the article, for example at least three times the thickness, for example at least 3.5 times the thickness, or at least four times the thickness.

[0225] Ex83B. An aerosol-generated article according to any of the foregoing examples, wherein the length of the article is between 25 mm and 35 mm, for example between 29 mm and 31 mm, for example about 30 mm.

[0226] Ex83C. An aerosol-generated article according to any of the foregoing examples, wherein the width of the article is between 8 mm and 15 mm, for example between 10 mm and 12 mm, for example about 11 mm.

[0227] Ex83D. An aerosol-generated article according to any of the foregoing examples, wherein the thickness of the article is between 2.5 mm and 3.5 mm, for example between 2.9 mm and 3.3 mm, for example about 3.1 mm, 3.2 mm or 3.3 mm.

[0228] Ex84. An aerosol generation system comprising an aerosol generation article and an aerosol generation apparatus configured to receive the aerosol generation article to generate an aerosol, the aerosol generation article being the article defined in any of the foregoing examples.

[0229] Ex85. An aerosol generation system comprising an aerosol generation article and an aerosol generation apparatus configured to receive the aerosol generation article to generate an aerosol, the aerosol generation system being, for example, the aerosol generation system according to Example Ex84.

[0230] The aerosol-generating article has a length extending in the x-direction between the distal and proximal ends, a width extending in the y-direction between the left and right sides, and a thickness extending in the z-direction between the upper and lower sides, wherein the length and the width are greater than the thickness.

[0231] The aerosol generating apparatus includes a product receiving cavity for receiving the aerosol-generated product for use.

[0232] The article is asymmetrically shaped such that the distal end of the article can be operatively engaged with the article receiving cavity, while the proximal end cannot be operatively engaged with the article receiving cavity.

[0233] Ex86. An aerosol generation system according to Ex85, wherein the width of the distal portion of the article is smaller than the width of the proximal portion of the article, and the article receiving cavity is sized to receive the article when inserted at the distal end of the article, but not when inserted at the proximal end of the article.

[0234] Ex87. An aerosol generation system according to Ex85 or Ex86, wherein the internal shape of the article receiving cavity is configured to match the external shape of the proximal portion of the aerosol-generated article when the article is operatively engaged with the article receiving cavity.

[0235] Ex88. An aerosol generating system according to any one of Examples Ex85 to Ex87, wherein the article is an article having a rounded distal corner as defined in Ex63, wherein the aerosol receiving cavity includes a distal end having a rounded corner to engage with the distal end of the aerosol generating article. Attached Figure Description

[0236] The examples will now be described further with reference to the accompanying drawings, in which:

[0237] Figure 1 A perspective view of an embodiment of an aerosol-generated article is shown;

[0238] Figure 2 It shows Figure 1 An exploded perspective view of the aerosol-generated product;

[0239] Figure 3 An exploded perspective view of another embodiment of the aerosol-generated article is shown;

[0240] Figure 4 An exploded perspective view of another embodiment of the aerosol-generated article is shown;

[0241] Figure 5 An exploded perspective view of another embodiment of the aerosol-generated article is shown;

[0242] Figure 6 An exploded perspective view of another embodiment of the aerosol-generated article is shown;

[0243] Figure 7 An exploded perspective view of another embodiment of the aerosol-generated article is shown;

[0244] Figure 8 A perspective view of an aerosol-generated article according to an embodiment of the present disclosure is shown;

[0245] Figure 9 It shows Figure 8 An exploded perspective view of the aerosol-generated product;

[0246] Figure 10 The diagram shown in the XY plane is shown. Figure 9 A cross-sectional plan view of the product;

[0247] Figure 11 An exploded perspective view of an article of manufacture according to another embodiment of the present disclosure is shown;

[0248] Figure 12 The diagram shown in the XY plane is shown. Figure 11 A cross-sectional plan view of the product;

[0249] Figure 13 The diagram shown in the YZ plane is as follows. Figure 11 A cross-sectional view of the proximal portion of the product (taken along line AA);

[0250] Figure 14 The diagram shown in the YZ plane is as follows. Figure 11 A cross-sectional view of the distal portion of the product (taken along line BB);

[0251] Figure 15An exploded perspective view of an article of manufacture according to another embodiment of the present disclosure is shown;

[0252] Figure 16 The diagram shown in the XY plane is shown. Figure 15 A cross-sectional plan view of the product;

[0253] Figure 17 A perspective view of an aerosol-generated article according to another embodiment of the present disclosure is shown;

[0254] Figure 18 It shows Figure 17 An exploded perspective view of the aerosol-generated product;

[0255] Figure 19 An exploded perspective view of an article of manufacture according to another embodiment of the present disclosure is shown;

[0256] Figure 20 An exploded perspective view of an article of manufacture according to another embodiment of the present disclosure is shown;

[0257] Figure 21 A schematic cross-sectional side view of an aerosol generating apparatus used as part of an aerosol generating system according to the present disclosure is shown;

[0258] Figure 22 It shows the relationship with Figure 8 The aerosol-generated products are subjected to operational bonding. Figure 21 A schematic cross-sectional side view of an aerosol generating device; and

[0259] Figure 23 It shows the relationship with Figure 8 The aerosol-generated products are subjected to operational bonding. Figure 21 A schematic cross-sectional plan view of the aerosol generation device. Detailed Implementation

[0260] Figures 1 to 7 An embodiment of an aerosol generating article for use with an aerosol generating apparatus to generate aerosols is shown. Figures 8 to 23 Various embodiments of aerosol-generating articles and aerosol-generating systems are shown. Figures 1 to 7 The descriptions help to understand these embodiments.

[0261] Figure 1An aerosol-generating article 10 is shown, comprising a first outer plane layer 24 forming a first outer plane surface 21, a second outer plane layer 25 forming a second outer plane surface 22, and a frame 50 positioned between the first outer plane layer 24 and the second outer plane layer 25. Both the first outer plane layer 24 and the second outer plane layer 25 comprise an aerosol-generating matrix containing an aerosol-generating material, i.e., tobacco. However, it should be understood that in some embodiments, only one of the first outer plane layer 24 and the second outer plane layer 25 may comprise an aerosol-generating matrix. Alternatively or additionally, the aerosol-generating matrix may be positioned elsewhere within the aerosol-generating article 10.

[0262] The aerosol generating article 10 has a length extending in the x-direction, a width extending in the y-direction, and a thickness extending in the z-direction. The aerosol generating article 10 has a length of 30 mm, a width of 10 mm, and a thickness of 3.1 mm.

[0263] The aerosol-generating article 10 is a substantially flat aerosol-generating article or a substantially planar aerosol-generating article. Specifically, the thickness of the aerosol-generating article 10 is less than 50% of both its length and width. The aerosol-generating article 10 has a generally rectangular cuboid shape and a laminated structure formed by a first planar outer layer 24, a frame 50, and a second planar outer layer 25. (The following text is about...) Figure 2 In more detail, the first outer plane layer 24, the frame 50, and the second outer plane layer 25 are bonded together with an adhesive, particularly guar gum.

[0264] Figure 2 It shows Figure 1 An exploded view of the aerosol-generated product 10.

[0265] Frame 50 has a length of 30 mm, a width of 10 mm, and a thickness of 2.7 mm. Frame 50 is made of cardboard and defines a frame opening extending through the thickness of frame 50. The frame opening at least partially forms cavity 30. Cavity 30 has a length of 26 mm, a width of 6 mm, and a thickness of 2.7 mm. Therefore, cavity 30 has a volume of approximately 421.2 cubic millimeters. In this embodiment, cavity 30 is substantially empty.

[0266] The frame 50 has an inner frame surface 52 extending in the z-direction or lateral direction between a first planar outer surface 21 and a second planar outer surface 22. The inner frame surface 52 defines an outer wall of a cavity. The frame 50 has an outer frame surface 53 extending in the z-direction or lateral direction between the first planar outer surface 21 and the second planar outer surface 22. The outer frame surface 53 at least partially defines one or more outer surfaces of an aerosol-generating article, such as a front wall 13 and a rear wall 14.

[0267] The frame 50 includes a peripheral wall 51 defining the cavity 30. More specifically, the peripheral wall 51 is defined by an inner surface 52 and an outer surface 52 of the frame. The peripheral wall 51 has a radial thickness of about 2 mm (as measured in the x / y plane between the inner surface 52 and the outer surface 53 of the frame).

[0268] The first outer plane layer 24 and the second outer plane layer 25 have a thickness of 200 micrometers and are in physical contact with the frame 50. The first outer plane layer 24 and the second outer plane layer 25 are bonded to the frame with adhesive 15. The first outer plane layer 24 defines at least a portion of the cavity 30. The second outer plane layer 25 defines at least a portion of the cavity 30.

[0269] The aerosol generating article 10 includes an air inlet 11 and an air outlet 12. The air inlet 11 and air outlet 12 are defined by and extend through a peripheral wall 51 of a frame 50. Each of the air inlet 11 and air outlet 12 has a rectangular cross-section, a width of 2 mm, and a thickness of 0.9 mm. An airflow passage extends through a cavity 30 between the air inlet 11 and air outlet 12.

[0270] Figure 3 It shows the relationship with Figure 1 An exploded view of an aerosol-generating article similar to the one described in section 10, except that the first outer planar layer 24 and the second outer planar layer 25 do not include the aerosol-generating matrix. Instead, the aerosol-generating matrix 40 is positioned within the cavity 30. The aerosol-generating matrix 40 comprises an aerosol-generating material in the form of tobacco shredded filler and has an aerosol forming agent content of 5% by weight (dry weight). As shown, the aerosol-generating matrix 40 fills the entire volume of the cavity 30. Figure 3 In one example, the aerosol generating matrix 40 has a filling density of about 0.87, a density of about 0.3 g / cm³, and a mass of about 110 mg. In another example, the aerosol generating matrix 40 can have different filling densities, different densities, and different masses. For example, the aerosol generating matrix can have a filling density of 0.64, a density of 0.35 g / cm³, and a mass of about 95 mg. In yet another example, the aerosol generating matrix can be in the form of aerosol generating beads, such as discrete free-flowing beads with an average bead diameter between 0.1 mm and 4 mm.

[0271] Figure 4 It shows the relationship with Figure 1 and Figure 3 Aerosol generating article 10 is similar to aerosol generating article 10, except that... Figure 4 The aerosol-generating article 10 includes an outer packaging 23 that defines a first planar outer surface 21 and a second planar outer surface 22 in place of the first planar outer layer 24 and the second planar outer layer 25.

[0272] Figure 5 It shows the relationship with Figure 1 Aerosol generating article 10 is similar to aerosol generating article 10, except that... Figure 5 The aerosol generating article 10 also includes a first aerosol generating matrix layer 41 and a second aerosol generating matrix layer 42. The first aerosol generating matrix layer 41 and the second aerosol generating matrix layer 42 are formed from aerosol generating material sheet. Specifically, the homogenized tobacco material sheet has an aerosol forming agent content of 5% by weight (dry weight). The first aerosol generating matrix layer 41 and the second aerosol generating matrix layer 42 each have a length equal to the length of the aerosol generating article 10, a width equal to the width of the aerosol generating article 10, and a thickness of 200 micrometers. That is, the aerosol generating article 10 has a length of 30 millimeters, a width of 10 millimeters, and a thickness of 3.5 millimeters.

[0273] The first aerosol generating matrix layer 41 and the second aerosol generating matrix layer 42 are in physical contact with the frame 50 and are bonded to the frame with adhesive 15. The first aerosol generating matrix layer 41 defines at least a portion of the cavity 30. The second aerosol generating layer 42 defines at least a portion of the cavity 30.

[0274] The first planar outer layer 24 is in physical contact with the first aerosol generating matrix layer 41 and is bonded together with adhesive 15. The second planar outer layer 25 is in physical contact with the second aerosol generating matrix layer 42 and is bonded together with adhesive 15.

[0275] Figure 6 It shows the relationship with Figure 5 An exploded view of aerosol generating article 10 similar to that of aerosol generating article 10, the difference being that the aerosol generating matrix 40 is as described above. Figure 3 The aerosol generating matrix 40 is located within cavity 30. It comprises an aerosol generating material in the form of tobacco shredded filler and has an aerosol forming agent content of 5% by weight (dry weight). As shown, the aerosol generating matrix 40 fills the entire volume of cavity 30.

[0276] Figure 7 It shows the relationship with Figure 5 Aerosol generating article 10 is similar to aerosol generating article 10, except that... Figure 7 The aerosol-generating article 10 includes an outer packaging 23 that defines a first planar outer surface 21 and a second planar outer surface 22 in place of the first planar outer layer 24 and the second planar outer layer 25.

[0277] Figure 8 It shows the relationship with Figure 1 A perspective view of aerosol-generating articles similar to aerosol-generating articles 80, the difference being... Figure 8 The geometry of the first outer plane layer 824, the second outer plane layer 825, and the frame 850 is similar to... Figure 1 The first outer plane layer 24, the second outer plane layer 25, and the frame 50 have different geometries. Figure 9 It shows Figure 8 An exploded view of the aerosol-generated product 80.

[0278] and Figure 1 Similarly, the first outer plane layer 824 forms the first outer plane surface 821, the second outer plane layer 825 forms the second outer plane surface 822, and the frame 850 is positioned between the first outer plane layer 824 and the second outer plane layer 825.

[0279] The aerosol-generating article 80 has a length extending in the x-direction, a width extending in the y-direction, and a thickness extending in the z-direction. The aerosol-generating article 80 has a length of 30 mm, a maximum width of 11 mm, and a thickness of 3.1 mm.

[0280] The aerosol generating article 80 includes a proximal face 814, a distal face 813, a left side face 817, and a right side face 818. The aerosol generating article 80 has a first proximal corner 847 defined between the left side face 817 and the proximal face 814; a second proximal corner 848 defined between the right side face 818 and the proximal face 814; a first distal corner 837 defined between the left side face 817 and the distal face 813; and a second distal corner 838 defined between the right side face 818 and the distal face 813. In this embodiment, the first proximal corner 847 and the second proximal corner 848 are rounded corners with a radius of 2 mm; and the first distal corner 837 and the second distal corner 838 are rounded corners with a radius of 1 mm. Therefore, the first distal corner 837 and the second distal corner 838 have smaller radii than the first proximal corner 847 and the second proximal corner 848, and the external shape of the aerosol-generating article 80 is asymmetrical in the x-direction.

[0281] The distance between the left side 817 and the right side 818 decreases towards the distal end 813. The distance between the left side 817 and the right side 818 begins to decrease at two-thirds of the length between the proximal end 814 and the distal end 813. In other words, the external shape of the aerosol generating article 80 begins to taper at a distance of 10 mm away from the distal end 813 (i.e., along the distal third of the article 80). By having a distal end that is narrower than the proximal end, the aerosol generating article 80 can be configured such that only the distal end can be inserted into the aerosol generating device first.

[0282] Frame 850 has a length of 30 mm, a maximum width of 11 mm, and a thickness of 2.8 mm. The maximum width is the lateral width at the widest point of the article. The outer profile of frame 850 in the XY plane is substantially the same as the outer profile of the first outer layer 824 and the second outer layer 825 in the XY plane. Frame 850 defines a frame aperture extending through the thickness of frame 850. The frame aperture at least partially forms cavity 830. Cavity 830 has a length of 14 mm, a maximum width of 8 mm, and a thickness of 2.8 mm. The maximum width of the cavity is the lateral width of the cavity at its widest point. Cavity 830 includes a proximal end 833 and a distal end 834. The width of cavity 830 at proximal end 833 is 7 mm. The width of cavity 830 at distal end 834 is 8 mm. Therefore, cavity 830 is narrower at distal end 833 than at proximal end 834, and cavity 830 is asymmetrical in the x-direction.

[0283] The asymmetry of the cavity reflects the asymmetry of the article. In this embodiment, the four internal corners of the cavity 830 are four rounded corners, each with a radius of 1.5 mm. In this embodiment, the midpoint 801 of the cavity 830 is positioned closer to the distal end face 813 than to the proximal end face 814. The midpoint 801 of the cavity is the midpoint of the cavity relative to both its length and width. Therefore, the cavity 830 is asymmetrically positioned within the article 80. The cavity is configured to hold an aerosol-generating matrix, such as an aerosol-generating matrix formed by multiple discrete beads of aerosol-forming material.

[0284] The frame 850 has an inner frame surface 852 extending in the z-direction or transverse direction between a first planar outer surface 821 and a second planar outer surface 822. The inner frame surface 852 defines the cavity wall. The frame 850 has an outer frame surface 853 extending in the z-direction or transverse direction between the first planar outer surface 821 and the second planar outer surface 822. The outer frame surface 853 at least partially defines one or more outer surfaces of the aerosol-generating article, such as a distal end face 813 and a proximal end face 814.

[0285] The first outer plane layer 824 and the second outer plane layer 825 each have a thickness of 150 micrometers, and... Figure 8 The cavity 830 is in physical contact with the frame 850. A first outer plane layer 824 and a second outer plane layer 825 are bonded to the frame with an adhesive (not shown). The first outer plane layer 824 defines at least a portion of the cavity 830. The second outer plane layer 825 defines at least a portion of the cavity 830. The cavity 830 is located between the first outer plane layer 824 and the second outer plane layer 825; between the proximal end face 814 and the distal end face 813; and between the left side face 817 and the right side face 818.

[0286] The aerosol-generating article 80 includes an air inlet 811 and an air outlet 812. The air inlet 811 extends between a distal face 813 and a distal end 833 of a cavity 830. The air inlet 811 has a length of 3 mm. The air outlet 812 extends between a proximal end 834 and a proximal face 814 of the cavity 830. The air outlet 812 has a length of 12 mm. In this embodiment, the air inlet 811 and the air outlet 812 each define a hollow channel having a rectangular cross-section, a width of 4 mm, and a thickness of 2 mm. An airflow path extends through the cavity 830 between the air inlet 811 and the air outlet 812. Therefore, air can enter the article through the air inlet, pass through the cavity containing the aerosol-forming matrix, and exit the article through the air outlet. The air outlet is longer than the air inlet.

[0287] The matrix cavity 830 is asymmetrically positioned toward the distal end of the article. This allows the entire matrix cavity to be inserted into the aerosol generating device for heating, while still allowing the article to protrude sufficiently from the device for the user to grasp and extract.

[0288] The longer air outlet also allows for more cooling of the aerosol after it leaves the heated zone of the matrix chamber and before it enters the user's inlet. This is because the longer air outlet prolongs the time it takes for heat to dissipate from the aerosol and provides a larger surface area of ​​the air outlet through which heat can dissipate before entering the user's inlet.

[0289] Aerosol formation by heating an aerosol matrix allows for the generation of moisture and slurry. This moisture and slurry can then be drawn towards the user during the use of the product. Providing a relatively long air outlet channel between the matrix cavity and the user allows some of this moisture and slurry to be retained by the walls of the air outlet and thus not transferred to the user.

[0290] In a particular embodiment, the aerosol-forming matrix is ​​in the form of a plurality of discrete, free-flowing beads of aerosol-forming material. The beads are substantially spherical. The beads have an average diameter between 1 mm and 2 mm, preferably about 1.5 mm, and a density of 1.3 g / cm³. The total weight of the beads in the matrix cavity is approximately 150 mg. The beads are formed from an aerosol-generating matrix comprising plant particles, an aerosol-forming agent, and a hydrocolloidal binder. Examples of suitable compositions of aerosol-generating matrices for forming the beads are provided below.

[0291] Examples of bead compositions

[0292] Suitable compositions for forming beads of the aerosol-generating matrix according to the present invention are listed in Table 1 below:

[0293]

[0294] All quantities are presented as a percentage of weight based on the total weight of the aerosol generating elements on a dry weight basis.

[0295] To prepare the beads, tobacco particles are first mixed with glycerin. An HPMC or CMC binder is dispersed in the glycerin, and water is then added to form an aqueous binder solution. This binder solution is added to the mixture of tobacco particles and glycerin, and all components are mixed to form a pellet. The pellet is extruded to form multiple discrete elements, and these discrete elements are then sphericalized at a low speed to form spherical beads with an average diameter of 1.5 mm. The beads are dried in an oven to the desired moisture content. As described above, the dried beads can then be incorporated into various aerosol-generating articles.

[0296] When such beads are incorporated into an aerosol-generating article as described herein and heated, an aerosol containing nicotine and glycerol is generated from the aerosol-generating matrix. It was found that the nicotine to glycerol ratio remained consistent throughout the duration of heating with each inhalation. This contrasts with aerosols generated from articles with a similar structure but in which the aerosol-generating matrix is ​​in the form of a tobacco cast leaf. In the case of the tobacco cast leaf matrix, it was found that the aerosol generated under the same conditions had a more variable nicotine to glycerol ratio with each inhalation. Providing an aerosol with a more consistent nicotine to glycerol ratio during inhalation provides the consumer with an optimal sensory experience throughout the duration of heating.

[0297] For exemplary purposes applicable to any of the embodiments described herein, a composition of an aerosol forming material that can be used to form a plurality of aerosol forming beads may be as follows. Percentages are given as a weight percentage relative to the product in its final state. The aerosol forming matrix may have about 5% to 25%, preferably about 7% to 15%, of moisture in the final product state. The aerosol forming matrix may also include the following:

[0298] 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 milled and graded into particles of about 100 to 380 mesh, preferably about 170 to 320 mesh.

[0299] 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.

[0300] 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.

[0301] 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.

[0302] 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.

[0303] "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.

[0304] For illustrative purposes, the composition of yet another aerosol forming matrix (which may also be suitable for use as an aerosol forming matrix in any of the embodiments described above) is described below. Percentages are given as weight percentages relative to the product in its final state. An aerosol forming matrix may comprise:

[0305] 1. An aerosol forming agent, such as glycerol; for example, about 10% to 40%, preferably about 20% to 30%.

[0306] 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.

[0307] 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.

[0308] 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, C...) obtained from Chaerophyllum macrospermum, Mesosphaerum sidifolium or other related plant varieties. 10 H 20 O, 2-isopropyl-5-methylcyclohexanol) and P-menthane-3-ol, which are any secondary alcohols such as diastereomers of 5-methyl-2-(propyl-2-yl)cyclohexane-1-ol.

[0309] Alternatively, such an aerosol-forming matrix 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.

[0310] Pellets formed from any such aerosol-forming material can be extruded to form multiple discrete elements, and these discrete elements can then be spheroidized at low speed to form substantially spherical beads with an average diameter between 0.5 mm and 4 mm. The beads are dried in an oven to the desired moisture content. As described herein, the dried beads can then be incorporated into a variety of different aerosol-generating articles.

[0311] Figure 10 It shows Figure 8 and Figure 9 A cross-sectional plan view of the article 80 in the XY plane shows the shape of the article in the XY plane, as well as the shapes of the air inlet 811, air outlet 812, and cavity 830. The midpoint 801 of the cavity is shown. In this embodiment, the air inlet 811 and air outlet 812 have the same width and thickness, but different lengths.

[0312] Figure 11 This is an exploded perspective view of an alternative embodiment of the aerosol-generating article 80A according to the present disclosure. The article is related to... Figure 8 The articles 80 are very similar, and similar features have similar reference numerals, which are distinguished by the suffix "A". Figure 8 The reference numerals are used to distinguish them. Figure 11In this design, air inlet 811A has a rectangular cross-section, a length of 3 mm, a width of 2.5 mm, and a thickness of 1 mm. Air outlet 812A has a rectangular cross-section, a length of 12 mm, a width of 4 mm, and a thickness of 2 mm. Therefore, air inlet 811A has a smaller cross-section than air outlet 812A.

[0313] Figure 12 It shows Figure 11 The cross-sectional plan view of article 80A in the XY plane shows the shape of the article in the XY plane, as well as the shapes of air inlet 811A, air outlet 812A, and cavity 830A. The midpoint 801A of the cavity is shown.

[0314] Figure 13 It shows Figure 11 and Figure 12 Cross-sectional view of product 80A in the YZ plane. The cross-section is along... Figure 12 The line marked AA is cut off 814 3 mm away from the proximal end face.

[0315] Figure 14 It shows Figure 11 and Figure 12 Cross-sectional view of product 80A in the YZ plane. The cross-section is along... Figure 12 The line marked BB is cut off at 813.3 mm from the distal end face.

[0316] It can be seen that, Figure 14 The air inlet 811A shown in cross-section is compared to the one in the middle. Figure 13 The air outlet 812A, shown in cross-section, has a smaller width, a smaller thickness, and therefore a smaller cross-sectional area. Furthermore, the slight taper towards the distal end of the article results in the cross-sectional width of article 80A along line BB (10 mm) being slightly smaller than the cross-sectional width along line AA (11 mm). By utilizing the slight taper of the distal portion of the article to provide asymmetry, the volume of the matrix cavity located in the distal portion of the article is unlikely to be significantly compromised. Therefore, the loading of the aerosol-generating matrix can be maximized while still providing unidirectional insertion of the article into the device. Moreover, if the width of the article at the distal end is not less than, for example, 15% of the width of the article at the proximal end, the ability to manufacture the article in a cost- and material-efficient manner can be optimized.

[0317] Figure 15 This is an exploded perspective view of an alternative embodiment of the aerosol-generated article 80B according to the present disclosure. Article 80B and... Figure 8 The articles 80 are very similar, and similar features have similar reference numerals, which are distinguished by the suffix "B". Figure 8 The reference numerals are used to distinguish them. Figure 15In the cavity 830B, air inlet 811B has a length of 4 mm and air outlet 812B has a length of 12 mm. Air inlet 811B has a smaller cross-sectional area at its distal end face 813B compared to its distal end face 833B. Similarly, air outlet 812B has a smaller cross-sectional area at its proximal end face 814B compared to its proximal end face 834B. Specifically, air inlet 811B has a width of 2.5 mm and a thickness of 1 mm at its distal end face 813B; and a width of 4 mm and a thickness of 2 mm at its distal end face 833B. Air outlet 812B has a width of 3 mm and a thickness of 1.5 mm at its proximal end face 814B; and a width of 4 mm and a thickness of 2 mm at its proximal end face 834B. Therefore, air inlet 811B and air outlet 812B have different minimum cross-sectional areas and different average cross-sectional areas in the YZ plane. The air inlet is shorter than the air outlet. Although air is drawn into the inlet and exits through the outlet, there is still a possibility of moisture and slurry leaking into the unit from the air inlet during operation. Therefore, a smaller average air inlet cross-sectional area can help prevent unwanted leaks through the air inlet.

[0318] Figure 16 It shows Figure 15 A cross-sectional view of article 80B shows the shape of the article in the XY plane, as well as the shapes of air inlet 811B, air outlet 812B, and cavity 830B. The midpoint 801B of the cavity is shown.

[0319] In other embodiments, the air inlet may have a larger cross-sectional area at the distal end of the cavity compared to the distal end of the cavity; and the air outlet may have a larger cross-sectional area at the proximal end of the cavity compared to the proximal end of the cavity.

[0320] Figure 17 and Figure 18 It shows the relationship with Figure 8 and Figure 9 Aerosol-generating products 80 are similar to aerosol-generating products 90, the difference being... Figure 17 and Figure 18 The geometry of the first outer plane 924, the second outer plane 925, and the frame 950 is similar to... Figure 1 The first outer plane layer 824, the second outer plane layer 825, and the frame 850 have different geometries. Therefore, Figures 15 to 16 Will only be about its relationship with Figure 8 and Figure 9 The differences are described. Figure 18 It shows Figure 17 An exploded view of the aerosol-generated product 90.

[0321] exist Figure 17 and Figure 18In the cavity 930, the first distal corner 937 and the second distal corner 938 are rounded corners, and the first proximal corner 947 and the second proximal corner 948 are right angles. Therefore, the aerosol generating article 90 can be more easily inserted into the aerosol generating apparatus, with the distal end face 913 entering the apparatus first. Each of the four corners of the cavity 930 is rounded and has an equal radius. In this embodiment, the cavity 930 has a rounded rectangular profile in the XY plane. The air inlet 911 is shorter than the air outlet 912, but both inlet 911 and outlet 912 have the same cross-sectional area.

[0322] Figure 19 This is an exploded perspective view of an alternative embodiment of the aerosol-generated article 90A according to the present disclosure. Article 90A and... Figure 17 The articles 90 are very similar, and similar features have similar reference numerals, which are distinguished by the suffix "A". Figure 17 The accompanying figure labels are used to distinguish them. Figure 19 Article 90A has an air inlet 911A that is shorter than the air outlet 912A. The cross-sectional area of ​​the air inlet 911A is smaller than the cross-sectional area of ​​the air outlet 912A.

[0323] Figure 20 This is an exploded perspective view of an alternative embodiment of the aerosol-generated article 90B according to the present disclosure. Article 90B and... Figure 17 The articles 90 are very similar, and similar features have similar reference numerals, which are distinguished by the suffix "B". Figure 17 The accompanying figure labels are used to distinguish them. Figure 20 Article 90B has an air inlet 911B that is shorter than the air outlet 912B. Both the air inlet 911B and the air outlet 912B of article 90B are tapered channels with minimum width at the distal and proximal ends of the article, respectively. The tapering of the inlet and outlet is essentially as described above regarding... Figure 15 As described in product 80B.

[0324] Figure 21A schematic cross-sectional view of an aerosol generating apparatus 900 configured for use with the aerosol generating article 80 described herein is shown. The aerosol generating apparatus 900 is an elongated aerosol generating device extending between a proximal end 91 and a distal end 92. The aerosol generating apparatus 900 includes a battery 93, a controller 94, a first heater 95, and a second heater 96 located within a housing 97. The controller 94 controls the power supply from the battery 93 to the first heater 95 and the second heater 96. A cavity 1000 is defined within the apparatus 900, having an opening 1010 defined in the proximal end 91 of the apparatus 900. The opening 1010 is rectangular in shape and sized to accommodate the maximum cross-section of the aerosol generating article 80. The cavity 1000 includes an upper planar surface 1020 and a lower planar surface 1030. A first heater 95 is located in the upper planar surface 1020 to heat the first planar outer surface 821 of the aerosol generating article 80 inserted into the cavity 1000, and a second heater 96 is located in the lower planar surface 1030 to heat the second planar outer surface 822 of the aerosol generating article 80 inserted into the cavity 1000. The first heater 95 extends partially along the upper planar surface 1020. The second heater 96 extends partially along the lower planar surface 1030. The device 900 includes an air inlet 98 defining an airflow path configured to allow air to flow from outside the device into the cavity 1000.

[0325] Figure 22 It shows the relationship with Figure 8 Aerosol-generated products 80% bonded Figure 21 A schematic cross-sectional view of the aerosol generating apparatus 900. There is virtually no tolerance between the first planar outer surface 821 and the second planar outer surface 822 of the aerosol generating article 80 and the inner surfaces 1020 and 1030 of the cavity 1000. Therefore, there is a tight fit between the aerosol generating article 80 and the aerosol generating apparatus 900. The apparatus is operable when the consumer has inserted the aerosol generating article 80 into the cavity 1000. A first heater 95 heats the first planar outer surface 821 of the aerosol generating article 80, and a second heater 96 heats the second planar outer surface 822 of the aerosol generating article, and thus heats the aerosol generating matrix in the aerosol generating article 80. The volatile components of the aerosol generating matrix evaporate and condense in the cavity 830 of the aerosol generating article 80 to form an aerosol. The consumer inhales the aerosol by suction at the end of the aerosol generating article 80, which includes an air outlet 812. Once the aerosol generating matrix has exhausted its volatile components, it is removed from cavity 1000 and the aerosol generating article 80 is discarded.

[0326] Figure 23A schematic cross-sectional plan view of an aerosol generating apparatus 900 engaged with an aerosol generating article 80 is shown. The cavity 1000 includes a left side surface 1040, a right side surface 1050, and a distal surface 1060. The distance between the left side surface 1040 and the right side surface 1050 decreases towards the distal surface 1060. In other words, the cavity 1000 tapers towards the distal surface 1060 such that only the distal end of the aerosol generating article 80 can be inserted into the cavity 1000 initially.

[0327] The dimensions of the distal end 813 of the article and the corresponding shapes of the article 80 and the device cavity 1000 mean that the article 80 is operatively engaged with the device 900 only when the distal end 813 of the article is inserted into the cavity 1000. This ensures that the air inlet 811 is inserted into the device to engage with the airflow passage defined in the device 900. When operatively engaged, preferably, a portion of the proximal end of the article 80 protrudes from the cavity 1000, or may be accessible to allow a user to remove the article from the cavity.

[0328] 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 that may or may not be specifically listed herein. Thus, in this document, the number A is understood to be A ± 10% of A. In this document, the number A may be considered to be a value within the general standard error of the measurement of the property modified by the number A. In certain instances 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. Moreover, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges that may or may not be specifically listed herein.

Claims

1. An aerosol generation system comprising an aerosol generation article and an aerosol generation apparatus configured to receive the aerosol generation article to generate an aerosol. The aerosol-generating article has a length extending in the x-direction between the distal and proximal ends, a width extending in the y-direction between the left and right sides, and a thickness extending in the z-direction between the upper and lower sides, wherein the length and the width are greater than the thickness. The aerosol generating apparatus includes a product receiving cavity for receiving the aerosol-generated product for use. The article is asymmetrically shaped such that the distal end of the article can be operatively engaged with the article receiving cavity, while the proximal end cannot be operatively engaged with the article receiving cavity.

2. The aerosol generation system according to claim 1, wherein the width of the distal end of the article is smaller than the width of the proximal end of the article.

3. The aerosol generation system according to claim 1 or 2, wherein the article receiving cavity is sized to operatively engage with the article when the distal end of the article is inserted into the cavity, but not to operatively engage with the article when the proximal end of the article is inserted into the cavity.

4. The aerosol generation system according to any of the preceding claims, wherein the internal shape of the article receiving cavity is configured to match or conform to the external shape of the proximal portion of the aerosol-generated article when the article is operatively engaged with the article receiving cavity.

5. The aerosol generation system according to any of the preceding claims, wherein the external shape of the aerosol-generated article is asymmetrical in the x-direction, for example, wherein the distal portion of the article is shaped differently from the proximal portion of the article.

6. The aerosol generation system of claim 5, wherein the distal portion of the article tapers, for example, in its width dimension.

7. The aerosol generation system according to claim 6, wherein the minimum width of the proximal portion of the article is greater than the minimum width of the distal portion of the article.

8. The aerosol generation system according to claim 6 or 7, wherein the lateral width of the article at a point 3 mm from the distal end of the article is less than the lateral width at a point 3 mm from the proximal end of the article, for example, less by 1% to 15%, or less by 2% to 10%.

9. The aerosol generation system according to any preceding claim, wherein the article comprises a proximal surface and a distal surface, the cavity being located between the proximal surface and the distal surface, wherein a first distal corner and a second distal corner, respectively defined between the distal surface and the left side surface and the distal surface and the right side surface, are rounded corners.

10. The aerosol generation system of claim 9, wherein the first proximal corner and the second proximal corner, respectively defined between the proximal surface and the left side surface and between the proximal surface and the right side surface, are rounded corners, and wherein the first distal corner and the second distal corner have smaller radii than the first proximal corner and the second proximal corner.

11. The aerosol generation system according to claim 9 or 10, wherein the first distal corner and the second distal corner have a radius between 0.5 mm and 2 mm, for example about 1 mm.

12. The aerosol generation system according to claim 9, 10 or 11, wherein the first proximal corner and the second proximal corner have a radius between 1 mm and 3 mm, for example about 2 mm.

13. An aerosol generating article configured for use in an aerosol generating system according to any of the preceding claims, for example, the aerosol generating article having a length extending in the x-direction between a distal and proximal end, a width extending in the y-direction between a left and right side, and a thickness extending in the z-direction between an upper and lower side, wherein the length and the width are substantially greater than the thickness, the aerosol generating article comprising a matrix cavity. The article is formed asymmetrically, such that the distal portion of the article is formed differently from the proximal portion of the article.

14. An aerosol generating article for use with an aerosol generating apparatus to generate an aerosol, such as the aerosol generating article according to claim 13, the aerosol generating article comprising: The first and second planar outer surfaces, the left and right sides, the proximal and distal surfaces, and the matrix cavity located within the article, wherein the first and second distal corners defined between the distal and left sides and between the distal and right sides are rounded corners.

15. The aerosol-generating article of claim 14, wherein the first proximal corner and the second proximal corner, respectively defined between the proximal surface and the left side surface and between the proximal surface and the right side surface, are rounded corners, and wherein the first distal corner and the second distal corner have a smaller radius than the first proximal corner and the second proximal corner.

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